ADdItive MAnufacture for next generation Composite applications (ADIMAC)

Utilisation of lightweight solutions in vehicles is key to UK's/EU's 2050 Net Zero. Enhancing the UK's capability to produce lightweight structures with advanced performance and lower manufacturing cost, addressing the needs of the global market, presents an enormous opportunity for jobs and prosperity. Currently, fibrous composites incorporated in a polymeric matrix are the most advanced solution for transport applications due to their exceptional combination of high strength and rigidity with a low specific weight. However, their manufacture is currently limited to standard inflexible solutions - mostly straight fibre layers and relatively thin structures assembled after primary production - and is expensive. These hinder the expansion of composite materials applications and limit the overall economic and sustainability opportunity.

ADIMAC puts forward a paradigm shift in composites manufacture through the development of a new process. The new process is based on the integration of two technologies established recently in the UK: (i) Rapid-Tow-Shearing (RTS) -- which is the world's first automated manufacturing process that can produce composites with curved fibre paths and; (ii) Layer-by-Layer (LbL) curing - a solution that allows fast and inexpensive production of thick composite components. The combination of these with developments around sequential processing and heating and tooling solutions will result in the Additive-Rapid-Tow-Shearing-Layer-by-Layer (ADD-RTS/LbL) process that will be capable to produce composite components with fibres following arbitrary curved orientations, unconstrained geometrical characteristics and optimised mechanical behaviour at low cost.

ADIMAC is led by iCOMAT, who are the originator of RTS, and includes Cranfield University, who have developed LbL curing, Hereaus Noblelight, who are world leaders in radiation heating solutions for manufacturing, and Prodrive who are one of the UKs largest manufacturer of composites using pre-impregnated materials for the automotive, motorsport and aerospace sectors. The consortium is supported by three aerospace end-users (Rolls-Royce, Spirit-AeroSystems, GKN-Aerospace) on an advisory-role.