Smart Tooling for Ceramic Profile Extrusion: Interdisciplinary exploration of innovation opportunities
Lead Research Organisation:
University of the West of England
Department Name: Fac of Arts Creative Ind and Education
Abstract
This project constitutes a second phase of a Leadership Fellowship award exploring innovation possibilities with the ceramic extrusion process. The method has been utilised for many decades in mass productions of architectural components, such as bricks and tiles. The process presents significant creative and commercial opportunities with the potential to be utilised in many other contexts and applications. Despite this innovation potential ceramic profile extrusion is significantly under researched, this research seeks to address this knowledge gap.
The proposed fellowship is centred on investigations into how digital fabrication technologies can be the basis for developing new approaches and materials via interdisciplinary applications for the process. The project builds on successful findings from the initial fellowship period which established a series of tools and processes to aid further research and utilisation of the ceramic profile extrusion method. These tools include innovative methods for 3D printing the extrusion profiles, known as 'dies', as well as the development of software scripts which facilitate non-specialists to design the dies through simple numeric controls. The first phase also established a concept for a low-cost hydraulic extrusion system. This system, combined with the software script and the methods for 3D printing the extrusion die, constitute a rapid development workflow that enables individual practitioners as well as industrial companies to engage in this innovation with the ceramic extrusion process. This second stage fellowship will provide the opportunity to build on the very promising potential of these results and expand the explorations into hybrid approaches introducing deployable elements to the extrusion dies. These explorations will seek to investigate the potential creation of hybrid extrusion and die moulding production methods - thus extending both the creative and technical application possibilities. Exploration of these tools, materials and processes into commercial contexts will be aided by extending successful research collaborations from phase one with the sector leading companies Wienerberger and Arup.
In addition, this project will utilise the knowledge foundations from phase one in entirely new interdisciplinary research partnerships to explore novel contexts and applications for the knowledge foundation. These include collaboration with the National Composite Centre (NCC) to explore the use of the ceramic extrusion process with composites for the production of parts for high performance applications in sectors such as aerospace and nuclear energy. Furthermore, this project will explore utilisation of the distinctive qualities of clay/ceramics to address the challenges in relation to sustainability and low carbon construction collaborating with Plymouth University's CobBauge project to investigate the possibility of extruding the traditional building material cob into building components.
Another main aim of this project is to further develop Dr Tavs Jorgensen's capacity for delivering interdisciplinary research leadership. This will be ensured through a range of activities including masterclasses, workshops and publishing research. This aim will be addressed in collaboration with other researchers across different disciplines, other HEIs and with world leading industry partners. The ambition is to develop capacity to actively raise the quality of the research environment in this interdisciplinary research area.
The project aims to be field-defining research that produces a new body of knowledge with a clear aim of extending the interdisciplinary research approach as wide as possible in the exploration of novel application for the ceramic profile extrusion process - in particular seeking to utilise the specific characteristic of ceramics to address the urgent issue of sustainability in design, manufacturing and construction.
The proposed fellowship is centred on investigations into how digital fabrication technologies can be the basis for developing new approaches and materials via interdisciplinary applications for the process. The project builds on successful findings from the initial fellowship period which established a series of tools and processes to aid further research and utilisation of the ceramic profile extrusion method. These tools include innovative methods for 3D printing the extrusion profiles, known as 'dies', as well as the development of software scripts which facilitate non-specialists to design the dies through simple numeric controls. The first phase also established a concept for a low-cost hydraulic extrusion system. This system, combined with the software script and the methods for 3D printing the extrusion die, constitute a rapid development workflow that enables individual practitioners as well as industrial companies to engage in this innovation with the ceramic extrusion process. This second stage fellowship will provide the opportunity to build on the very promising potential of these results and expand the explorations into hybrid approaches introducing deployable elements to the extrusion dies. These explorations will seek to investigate the potential creation of hybrid extrusion and die moulding production methods - thus extending both the creative and technical application possibilities. Exploration of these tools, materials and processes into commercial contexts will be aided by extending successful research collaborations from phase one with the sector leading companies Wienerberger and Arup.
In addition, this project will utilise the knowledge foundations from phase one in entirely new interdisciplinary research partnerships to explore novel contexts and applications for the knowledge foundation. These include collaboration with the National Composite Centre (NCC) to explore the use of the ceramic extrusion process with composites for the production of parts for high performance applications in sectors such as aerospace and nuclear energy. Furthermore, this project will explore utilisation of the distinctive qualities of clay/ceramics to address the challenges in relation to sustainability and low carbon construction collaborating with Plymouth University's CobBauge project to investigate the possibility of extruding the traditional building material cob into building components.
Another main aim of this project is to further develop Dr Tavs Jorgensen's capacity for delivering interdisciplinary research leadership. This will be ensured through a range of activities including masterclasses, workshops and publishing research. This aim will be addressed in collaboration with other researchers across different disciplines, other HEIs and with world leading industry partners. The ambition is to develop capacity to actively raise the quality of the research environment in this interdisciplinary research area.
The project aims to be field-defining research that produces a new body of knowledge with a clear aim of extending the interdisciplinary research approach as wide as possible in the exploration of novel application for the ceramic profile extrusion process - in particular seeking to utilise the specific characteristic of ceramics to address the urgent issue of sustainability in design, manufacturing and construction.
Organisations
- University of the West of England (Fellow, Lead Research Organisation)
- National Composites Centre (NCC) (Collaboration)
- University of Plymouth (Collaboration)
- Rolls Royce Group Plc (Collaboration)
- Ibstock Brick Limited (Collaboration)
- Arup Group (Collaboration)
- Wienerberger Ltd (Project Partner)
- National Composites Centre (Project Partner)
- Arup Group (United Kingdom) (Project Partner)
People |
ORCID iD |
Tavs Jorgensen (Principal Investigator / Fellow) |
Publications
Jorgensen T
(2022)
Towards a standard: Designing an open-source clay measuring tool
Jorgensen, T
(2022)
New approaches with ceramic profile extrusion
Title | 3D Toolprinting for Clay Extrusion |
Description | This exhibition showcases the use of 3D printing to create tools for research explorations into clay extrusion. The tools exhibited are the extrusion profiles - also know as dies, which are most central part of the process. The exhibition also includes examples of the creative outputs of the research. |
Type Of Art | Artwork |
Year Produced | 2022 |
Impact | Transfer of knowledge of research process and methodology to new audiences in the printmaking community |
URL | https://cfpr.uwe.ac.uk/impactconference12/home/exhibitions/ |
Title | Artful Craft |
Description | An exhibition of extruded porcelain pieces part of group exhibition |
Type Of Art | Artwork |
Year Produced | 2022 |
Impact | Exposure of research outcome to the public. The group exhibition curated by Peter Randell-Page RA featured some of the UK leading Makers including Alice Dudgeon, Amanda Cobbett, Amy Shelton, Andrea Liu, David Mach RA, David Nash RA OBE, Halima Cassell MBE, Jonathan Keep, Marcus Vergette, Peter Randall-Page RA, Sarah Gillespie, Susan Derges, Tavs Jørgensen |
URL | https://makesouthwest.org.uk/all-exhibitions/artful-craft |
Title | Extruded Porcelain Twisted vases |
Description | A series of twisted porcelain vases produced via 3D printed dies developed during this research. |
Type Of Art | Artefact (including digital) |
Year Produced | 2022 |
Impact | Vases exhibited at the launch event of Make South West Gallery, Bovey Tracy, UK. |
Description | The new phase is structured with new objectives but there is a degree of overlap in the core research aim from the initial phase of research. As a result outputs and impact activities will have overlab from objectives of the previous phase of the fellowship. The aim of the second phase of the leadership fellow project is to utilize the knowledge developed in first phase to explore new directions for the research - in particular to exploit the potential for innovation in unexpected applications and sectors that the interdisciplinary approach in this project has fostered. To reiterate the project's core objectives in this overarching aim: • To explore the extrusion of fibre/ceramic composite to produce parts (pipes in particular) for high-performance applications in sectors such as aerospace nuclear. • To explore the use of extrusion concepts established in fellowship's first phase in novel applications for producing prefabricated cob building components • To investigate additional technical aspects that have arisen in the first phase of the research, and have been identified, but remain unexplored. • Through knowledge exchange and dissemination activities to develop further routes for utilising knowledge generated in the research in new contexts and to maximise impact of research. There are significant findings in relation to the initial objective. Experiments have successfully established a firm proof of concept of extruding fibrous ceramics compounds also known as Ceramic Matrix Composites (CMC). Particular geometries used for the extrusion dies have been developed which enable long ceramic fibre (up to 12mm) composites with high surface fidelity to be produced. CMC pipes have successfully been produced using design approached established in the research. These approaches have been extended with experiments of using integrated coating capacities on both the internal and external surfaces of the extrudes. The findings of the CMC tests are now forming the foundation of early-stage experiments with Cob mixtures for low carbon building components (second objective). Further interaction with CobBauge team at the University of Plymouth has been undertaken to inform the experiments with knowledge from this research project. Additional experiments to extend the technical capabilities the low-cost hydraulic extruder system established in phase one have also been undertaken. A capability of using the system in vertical position has been developed. This capability has facilitated a new body of the creative work to be developed. This research feature specialist dies that create twisted forms. Initial outcomes of this research have been the production of series of porcelain vases. This new body of creative ouput have so for been disseminated through 3 exhibitions to both academic and non-academic audiences. |
Exploitation Route | Commercial exploitation by the architectural ceramic industry. Use of the knowledge by creative practitioners and small business. The research has attracted interest from other disciplines and and sectors. This is evidenced by material sponsorship from Rolls Royce (Aerospace) but there are multiple ongoing conversation with commercial contacts in diverse sectors such as construction, agriculture and biotechnology |
Sectors | Aerospace, Defence and Marine,Construction,Creative Economy,Energy,Environment,Manufacturing, including Industrial Biotechology,Culture, Heritage, Museums and Collections,Pharmaceuticals and Medical Biotechnology |
Description | Through the public exhibitions of creative artefacts there are indications that cultural impact of the research is being recognised and valued. There are also indications that the research is attracting significant interest from manufacturing industries, for example we are currently undertaking trail for the use of 3D printed extrusion dies for the use in Ibstock PLC's production of specialised bricks. |
First Year Of Impact | 2023 |
Sector | Construction,Creative Economy,Manufacturing, including Industrial Biotechology,Culture, Heritage, Museums and Collections |
Impact Types | Cultural,Economic |
Description | Ceramic Extrusion Collaboration with Arup |
Organisation | Arup Group |
Country | United Kingdom |
Sector | Private |
PI Contribution | Development input to infrom Arup's building facade team. |
Collaborator Contribution | Consultation to guide and inform research from an industry perspective and to insure commercially relevant impact of the research. |
Impact | Specific outputs and impact outcomes are still in development. |
Start Year | 2019 |
Description | Collaboration with Ibstock Plc |
Organisation | Ibstock Brick Limited |
Country | United Kingdom |
Sector | Private |
PI Contribution | Exploration commercial exploration have begun with this company. Early scale trails have been undertaken which utilise knowledge from this research in Ibstock production of specialist brick at the Cattybrook site in Bristol. KTP opportunities are being explored. |
Collaborator Contribution | Hosting visit to the Cattybrook, contribution of industrial know-how and commercial problem posing |
Impact | Early practical tests results |
Start Year | 2022 |
Description | Collaboration with National Composite Centre |
Organisation | National Composites Centre (NCC) |
Country | United Kingdom |
Sector | Private |
PI Contribution | The initial phase has developed a promising collaboration with the NCC, with exchange of knowledge for the potential commercial exploitation. |
Collaborator Contribution | In kind time for advise and facilitating link with commercial companies |
Impact | Specific output and outcome still in process. The collaboration is multidisciplinary, with disciplines including: engineering, design, science, |
Start Year | 2020 |
Description | Collaboration with University of Plymouth |
Organisation | University of Plymouth |
Country | United Kingdom |
Sector | Academic/University |
PI Contribution | Exchange of knowledge from new extrusion processes |
Collaborator Contribution | Contribution of knowledge from Cob building research |
Impact | Output and Outcome still in progress. The collaboration is multidisciplinary, disciplines including: design, construction, science |
Start Year | 2021 |
Description | Material Sponsorship by Rolls Royce |
Organisation | Rolls Royce Group Plc |
Country | United Kingdom |
Sector | Private |
PI Contribution | Undertaking test with supplied Ceramic Matrix Composites (CMC) |
Collaborator Contribution | Ceramic Matrix Composites (CMC) Material |
Impact | The collaboration facilitated success tests of extrusion with Ceramic Matrix Composites (CMC). This collaboration is multidisciplinary (design, craft , ceramics, aerospace engineering) |
Start Year | 2022 |
Description | Bristol print innovators make a strong impression |
Form Of Engagement Activity | A magazine, newsletter or online publication |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Other audiences |
Results and Impact | Journal article featuring research and research methodologies |
Year(s) Of Engagement Activity | 2023 |
URL | https://physicsworld.co...ke-a-strong-impression/ |
Description | Exhibition at Future Textiles |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Professional Practitioners |
Results and Impact | Research exhibition at the Future Textile conference. |
Year(s) Of Engagement Activity | 2023 |
URL | https://cfpr.uwe.ac.uk/future-textiles-conference/ |
Description | Materials Research Exchange (MRE) 2022 |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Industry/Business |
Results and Impact | Exhibition stand at the Materials Research Exchange (MRE) 2022. Participation resulted in a number of industry connections and collaborations opportunities. |
Year(s) Of Engagement Activity | 2022 |
URL | https://iuk.ktn-uk.org/events/materials-research-exchange-mre-2022/ |
Description | On Line panel discussion for ArtFul Craft Exhibition |
Form Of Engagement Activity | A broadcast e.g. TV/radio/film/podcast (other than news/press) |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Professional Practitioners |
Results and Impact | Live online panel discussion with key participants in the ArtFul Craft Exhibition to mark the launch of the Artful Craft exhibition at MAKE Southwest, Peter Randall-Page RA, artist, MAKE Southwest president, and curator of the exhibition, chaired a Q&A with a handful of the exhibitors. The panel is Halima Cassell MBE, Jonathan Keep, Tavs Jørgensen, Alice Dudgeon and Andrea Liu. Presented by Exhibitions Manager Flora Pearson. |
Year(s) Of Engagement Activity | 2022 |
URL | https://www.youtube.com/watch?v=taJ-050j7JQ |