Future Additive Manufacturing Platform Grant

Lead Research Organisation: University of Nottingham
Department Name: Faculty of Engineering

Abstract

The Additive Manufacturing & 3D Printing Research Group (3DPRG) at The University of Nottingham (UoN) is focused on the discovery and understanding of advanced Additive Manufacturing (AM) solutions for high value manufacturing and further advanced research applications. The foundations of the 3DPRG go back to the early 1990s and Richard Hague, Ian Ashcroft, Phill Dickens, Chris Tuck and Ricky Wildman have worked collaborated since the mid-2000s. This successful relationship was formalised in 2011 by the award of the EPSRC Centre for Innovative Manufacturing in AM and crystallised with our move to UoN in 2012. Our academic grouping was further strengthened through the promotion to academic positions of Ruth Goodridge (2012) and Martin Baumers (2016). Together, we are a clearly established research group of scale that is internationally recognised as undertaking leading work in the field of AM. We have a strong track record in obtaining grant funding, of joint publications and of achieving impact (academic, industrial and societal).

With expertise and track record in both single and multi-material / multifunctional AM, our research approach is both user-centred and scientifically driven. Alongside strong and enduring interdisciplinary links to the physical and applied sciences that complement and extend our capabilities, we have built a core multi-disciplinary team of academics and researchers of ~100 people, housed in a purpose built laboratory. Our goal is to investigate the underpinning processes, materials and computational methods necessary for the successful execution and implementation of AM as a viable manufacturing tool. Our interest and focus on underpinning AM leads us to work with diverse industrial sectors and key (international) manufacturing companies to enable unique AM solutions across a myriad of applications.

With a strong history of research in AM, the UK now needs to capitalise on its deep fundamental knowledge-base to successfully implement AM in industry. However, as highlighted by the UK AM Strategy's interim report [], the range of technologies that are now being industrially deployed are primarily based on technological developments that are over 20 years old (first introduced for prototyping purposes) and there remain significant barriers to productivity in terms of the speed, reproducibility, accuracy, material range and functionality of produced parts. Hence, today's AM technologies are largely still not ready for implementation into most production environments, nor are they capable enough to service the needs of potential users, particularly when it comes to productivity issues (speed of production or material utility).

Our vision driving this platform proposal is to discover, understand and enable industrial implementation of AM solutions to address the issues of productivity and industrial scalability, with our ambition being that this will strengthen our engagement across the full value chain from discovery to deployment. This vision will require close relationships with all stakeholders, including academics in disparate disciplines; the wider innovation ecosystem (particularly the Catapults); manufacturers of AM equipment and materials; organisations involved in policy making; as well as end users in multiple industry sectors.

This Platform proposal is therefore centred on both addressing a subject of undoubted (inter)national importance alongside sustaining a research group of international renown. It will enable us to renew our long term research vision, through the exploration and exploitation of new and emerging science, whilst maintaining a focus on overcoming the challenges associated with implementing AM into industry.

Planned Impact

Impact will be derived for the following:

- UK industry will gain impact through new research that further enhances the UK's leading position in AM technology and exploitation. We will open up awareness in industries yet to exploit AM, and impact existing products and new product conception and realisation, with corresponding economic, societal, healthcare and environmental benefits.
- The HVM Catapult (through the MTC) and its members will gain impact by exploiting the outcomes of lower TRL activities
- AM equipment and service providers will have first-mover advantage in benefitting from new research that will expedite their exploration of the design freedoms of AM and enable faster implementation of innovative products.
- The 3DPRG's research staff will benefit through enhanced career development, a multi-skilled working environment, opportunities to explore new 'risky' concepts and ideas, and an ever-widening network of academic / industrial partners.
- The University of Nottingham will benefit from further enhancing its internationally leading AM research, and in furthering interdisciplinary research both within the University and beyond.
- Doctoral Students will benefit through opportunities to debate new ideas and formulate research proposals, exposure to new high risk research projects, and to understand how to translate academic research into industrial practice.
- The public and society as a whole will benefit through job creation, and the potential for industry to robustly adopt a new and disruptive technology that will enable environmental, healthcare and economic gains.

Publications

10 25 50
 
Description The platform grant is primarily aimed at bridging and retention of key staff alongside pump priming new areas of work. New areas of work are at the have been developed through the platform with a particular focus on novel functional materials for AM alongside associated processing technologies (especially multi material)
Exploitation Route Currently discussing further projects with HVM Catapult (particularly MTC)
Through spin out company Added Scientific Ltd
Sectors Aerospace, Defence and Marine,Agriculture, Food and Drink,Chemicals,Education,Electronics,Energy,Government, Democracy and Justice,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology,Transport

 
Description We have engaged with multiple industries through the purpose-created spin out Added Scientific Ltd
First Year Of Impact 2017
Sector Aerospace, Defence and Marine,Chemicals,Electronics,Energy,Healthcare,Government, Democracy and Justice,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology
Impact Types Societal,Economic,Policy & public services

 
Description AM Strategy (P Dickens). The AM Strategy has been cited in the Made Smarter Review 2017 and submitted a response to the Industrial Strategy Consultation Process
Geographic Reach National 
Policy Influence Type Contribution to a national consultation/review
URL https://www.gov.uk/government/publications/made-smarter-review
 
Description Additive Manufacturing and 3D Printing in Clinical Practice
Amount £158,815 (GBP)
Funding ID EP/S02882X/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 09/2019 
End 03/2022
 
Description Complex Materials for Advanced Device Fabrication Through the Combination of Holographic Optical Tweezers and Multiphoton Absorption
Amount $146,700 (USD)
Organisation United States Air Force 
Sector Public
Country United States
Start 03/2017 
End 02/2018
 
Description Dialling up performance for on demand manufacturing
Amount £5,865,536 (GBP)
Funding ID EP/W017032/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2022 
End 09/2027
 
Description EPSRC Early Career Research Block Grant ( N Aboulkhair, M Simonelli)
Amount £60,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 10/2018 
End 10/2019
 
Description EPSRC/BP iCASE PhD studentship: The Synthesis and Continuous Manufacture of Novel, High Performing Polymeric Lubricants for the Next Generation of Electric Transportation (Irvine) (Irvine)
Amount £116,928 (GBP)
Organisation BP (British Petroleum) 
Sector Private
Country United Kingdom
Start 10/2020 
End 09/2024
 
Description Hermes Fellowship programme administered through the University of Nottingham (Dr Ian Maskery)
Amount £25,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 02/2018 
End 07/2018
 
Description IEG - Evaluation of Novel Tyre Manufacturing Formulation (SW)
Amount £8,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 01/2020 
End 03/2020
 
Description Imaging Mechanical Strength in Advanced Materials (Equipment grant opportunity for ERC)
Amount £60,000 (GBP)
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 12/2018 
End 03/2020
 
Description Intelligent Structures for Low Noise Environments
Amount £1,703,189 (GBP)
Funding ID EP/S03661X/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 12/2018 
End 11/2023
 
Description J Ding, M Baumers, R Wildman- AM Pharmaceutical Policy (UoN Smart Product Beacon)- Bridging the policy gap for manufacturing pharmaceuticals in smarter ways
Amount £12,500 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 12/2019 
End 02/2020
 
Description NSF-EPSRC A Transatlantic Institute for Volumetric Powder Bed Fusion
Amount £254,060 (GBP)
Funding ID EP/R02460X/1 
Organisation Engineering and Physical Sciences Research Council (EPSRC) 
Sector Public
Country United Kingdom
Start 10/2017 
End 09/2020
 
Description Nottingham - BEACON -SOLARIS (Subsumptive Optimisation for Layered Additive Reactive Industrial Systems)- MB
Amount £97,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 11/2019 
End 10/2020
 
Description Public engagement Grant (£5,000): 'Policy Impact Small Grant' (Jin Ding, M Baumers)
Amount £5,000 (GBP)
Organisation University of Nottingham 
Sector Academic/University
Country United Kingdom
Start 03/2019 
End 08/2019
 
Description Silicone Jetting
Amount £356,477 (GBP)
Organisation Atomic Weapons Establishment 
Sector Private
Country United Kingdom
Start 01/2019 
End 01/2021
 
Description Hilti Corporation Confidentiality Agreement 
Organisation Hilti Group
Country Liechtenstein 
Sector Private 
PI Contribution Research collaboration with industry partner. We contribute additive manufacturing research results.
Collaborator Contribution Industrial knowledge and application of our research results
Impact multidisciplinary collaboration
Start Year 2019
 
Description ITA- Brazil 
Organisation Technological Institute of Aeronautics
Country Brazil 
Sector Academic/University 
PI Contribution Collaboration on a research project, Hierarchical design of multi-material alloys producing components for 3D printing.
Collaborator Contribution Instituto Tecnológico de Aeronáutica (ITA), has been awarded finding by Fundacao de Amparo a Pesquisa do Estado de Sao Paulo (FAPESP) towards its activities under the project
Impact Currently, a conference paper has resulted from this collaboration, Optimisation of Fibre-Paths in Composites Produced by Additive Manufacturing, in book EngOpt 2018 Proceedings of the 6th International Conference on Engineering Optimization (Jan 19) The research partners are still working on three other papers which will be published in due course.
Start Year 2018
 
Description JFE steel corporation, Japan 
Organisation JFE Steel Corporation
Country Japan 
Sector Private 
PI Contribution The Centre for Additive Manufacturing at UoN will produce a demonstrator made of tin on a copper substrate using the droplet-on-demand technology Metaljet. The demonstrator is to be fabricated from Sn will be the JFE steel corporation logo. This logo will be printed on a 50*40 mm2 substrate. The research team will produce a report detailing the experimental conditions and results (droplet, velocity, etc). Photos (observation result of droplet collision behaviour) will be included.
Collaborator Contribution The collaborator provides the financial support for the study by taking responsibility for all the expenses for the experiments.
Impact The output from this study will be the demonstrator that will be provided to the sponsor.
Start Year 2018
 
Title ADDITIVE MANUFACTURING 
Description A method (300) of fabricating an object by additive manufacturing comprises providing (310) a layer of polymeric material (100), said polymeric material (100) being in particulate form, and comprising linear polymer chains, selectively depositing (320) a reactive liquid (200) onto the layer of particulate polymeric material (100), said reactive liquid (200) comprising reactive units (210a) which are monomeric units, linear oligomeric units, linear polymeric units, or combinations thereof, wherein said reactive units (210a) have two or fewer reactive groups, and allowing (330) linear polymeric chains in said layer of polymeric material (100) to react with reactive units in said reactive liquid (200) so as to form extended polymeric chains that are linear, so as to provide a shaped layer of linear polymer. These steps (310, 320, 330) are repeated as required to form the object from successive shaped layers of linear polymer. 
IP Reference WO2018083500 
Protection Patent application published
Year Protection Granted 2018
Licensed No
Impact The market for AM reached US$5.165B p.a. in 2016 (Wohlers Report). However, market growth for polymeric AM was limited due to production costs, processing speed and narrow material choices. Our technique can overcome these limitations. Compared to the highly competitive metal AM market, there is less direct competition especially for a disruptive new technique which can overcome most of the limitations of existing AM techniques. Customers for a fully commercialized system based on our techniqu
 
Title METHOD FOR PRODUCING A POLYCARBONATE ARTICLE 
Description A method for producing a polycarbonate article comprises printing a droplet onto a target location in a build area to obtain a printed droplet, wherein the droplet comprises a precursor solution comprising a precursor composition, a catalyst, and a solvent; removing at least a portion of the solvent from the printed droplet to obtain a bead comprising a precursor precipitate, wherein the precursor precipitate comprises the precursor composition and the catalyst; repeating the printing step and the removing step adjacent to or on the bead to obtain a plurality of adjacent beads comprising precursor precipitates; and polymerizing the precursor precipitates to obtain the polycarbonate article. 
IP Reference WO2019048986 
Protection Patent application published
Year Protection Granted 2019
Licensed No
Impact This work helped building understanding of the complexity of reactive inkjet printing for step growth polymers, including handling of the condensates and getting sufficient conversion on the surface, after being jetted. A range of derivative IPs could be potentially generated from this fundamental work, including but not limited to the composite materials, modified polycarbonate with alternative curing mechanisms, post-processing development and QA etc.
 
Description Brilliant Club - 2020-2021 - Marica Malenica 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Schools
Results and Impact PhD student Marica Malenica has been holding tutorials (in person and virtual) on 3D printing in high schools around UK. The tutorials are aimed at pupils aged 13-17.
She is doing this as a volunteer of charity organisation called the Brilliant Club, which encourages pupils from underrepresented backgrounds to enrol highly selective universities. In tutorials she also talks about my PhD research and promote the work of the Centre for Additive Manufacturing.
So far, she has worked with around pupils from 2 high schools, in Nottingham and Dereham, Norfolk.
Year(s) Of Engagement Activity 2020
 
Description Co-host: Additive International Conference 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Additive International is the premier summit for academic and industrial leaders in Additive Manufacturing and 3D Printing. Since 2006, we have showcased next-generation technology and the latest thinking, providing a forum for practitioners to build their networks and drive innovation.
Year(s) Of Engagement Activity 2018
URL http://www.additiveinternational.com
 
Description Festival of Science and Curiosity (FOSAC) 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Public/other audiences
Results and Impact Team of CfAM PhD students running a community stand in the local shopping centre. Explaining 3DP to the general public (pre-prepared interactive activities, visuals, Ultimaker live printing) and showing some of the research being investigated at UoN in a broader context (biomedical, automotive etc).
Throughout the event, they demonstrated the advantages and limitations of FDM printing with a live print of a rocket using an Ultimaker 2 Go printer, capturing genuine interest and engagement from all ages.
Year(s) Of Engagement Activity 2020
 
Description IOP PGS Conference: Printing for the future 2018, CfAM: co-organisers 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact The Institute of Physics (IOP) in collaboration with CfAM have organised Printing for the future 2018 conference. Dr. Ehab Saleh from CfAM is a committee member of the Printing and Graphics Science group (PGS) was a primary organiser of the event which attracted students and academic staff from across the UK presenting their latest research achievements in printing technologies. The main conference outcome was: New routes of collaborations were highlighted. This was significant in the Q&A sessions were speakers were invited to follow up their discussions during break, and dialogues progressed throughout the day.
Year(s) Of Engagement Activity 2017
 
Description Ingenuity Breakfast Event- 3D Printing - tool or toy? (M Baumers)- TO UPDATE 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Industry/Business
Results and Impact Ingenuity activities are designed to bring business into contact with the resources, knowledge and experience of this world-class, research-led university.
Martin Baumers made a presentation with title "3D Printing - tool or toy?" In this talk, he presented the latest results on the performance of 3D printing in real-world applications and some of the challenges of the technology, like integration with other manufacturing methodologies, quality assurance and cost. He provided an insight into the type of highly functional, durable and life-changing items that researchers are pushing the technology towards being capable of producing; things like prosthetic limbs, complex pharmaceutical devices and advanced engineering components.
Year(s) Of Engagement Activity 2019
 
Description Inspiring Women in STEM Programme 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact PhD students at CfAM are participating in this events aiming to combat the gender imbalance in STEM sectors and inspire female school students to consider applying for STEM subjects (at A-Levels and the University) by delivering several practical sessions.
Year(s) Of Engagement Activity 2021
 
Description J Ding, M Baumers- Overcoming Policy Roadblocks to the Application of 3D Printed Drug Innovation: Identifications and Solutions 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Policymakers/politicians
Results and Impact 3D printing is now gaining increasing attention in the pharmaceutical industry. The process involves 3D layer-by-layer fabrication to formulate materials into the desired dosage form, geometric structure, and controlled release formulation. 3D printing, with the ability to produce on-demand, personalized products, is predicted to deliver more precise drugs and improve medication adherence. Currently, there is no regulatory framework supporting 3D printed drugs in the UK. The uncertainties brought about by regulation and policy slow down the application of this innovative technology.
This Horizon Scanning workshop brought a cross-section of actors together in the 3D drug printing ecosystem to share their perspectives and knowledge to 'scan' how 3D printing technology might influence the future. It is aimed at laying the groundwork for shaping the policy for 3D printed drugs, and thereby gaining an opportunity for the UK pharmaceutical industry to leverage 3D printing and enhance the quality of public healthcare. The outcome of the research will be summarised in a policy brief for dissemination.
Year(s) Of Engagement Activity 2019
 
Description Materialise World Summit in Brussels (Prof Richard Hague) 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact In April 2017, Prof Richard Hague was invited to the panel of the Materialise World Summit in Brussels. The panel's topic was: Are We Prepared for an Additive Future?
Year(s) Of Engagement Activity 2008,2017
 
Description OPAD - Cascade grant 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Regional
Primary Audience Undergraduate students
Results and Impact Talk by a Trauma and Orthopaedic surgeon on "Broken bones and the challenges they present". OPAD is a project that was started in 2016 within the Department of Mechanical, Materials and Manufacturing Engineering. It is funded by Cascade and the Centre for Additive Manufacturing. OPAD is a project that exposes students to real life challenges and gives them the opportunity to work collaboratively in groups to create assistive devices. Students also get the chance to meet with volunteers to find out what specific needs they have and design an assistive device for them.
In March 2018 it was organised a Talk by a Trauma and Orthopaedic surgeon on "Broken bones and the challenges they present" as part of OPAD spring programme for students.
Year(s) Of Engagement Activity 2016,2017,2018
 
Description POSTnote - March 2020 
Form Of Engagement Activity A talk or presentation
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Postgraduate students
Results and Impact Jin Ding was invited to review the POSTnote about '3D Bioprinting in Medicine', which gives an overview of 3D bioprinting in regenerative medicine and the associated biological, manufacturing, regulatory and ethical implications. The POSTnote is a summary of public policy issues published by the Parliamentary Office of Science and Technology (POST), it is based on literature reviews and interviews with a range of stakeholders and externally peer-reviewed. The objective of POSTnotes is to inform parliamentarians about the advance knowledge of key issues in 3D bioprinting area before the upcoming parliamentary debates. It is published on 13th March 2020 at UK parliament website https://post.parliament.uk/research-briefings/post-pn-0620/
Year(s) Of Engagement Activity 2020
URL https://post.parliament.uk/research-briefings/post-pn-0620
 
Description Press release: New method developed to 3D print fully functional electronic circuits 
Form Of Engagement Activity A press release, press conference or response to a media enquiry/interview
Part Of Official Scheme? No
Geographic Reach International
Primary Audience Professional Practitioners
Results and Impact Nov 2017: Press release: New method developed to 3D print fully functional electronic circuits. Published also in The Engineer, TCT magazine and over 50 international science news websites.
Year(s) Of Engagement Activity 2016,2017
URL https://www.nottingham.ac.uk/news/pressreleases/2017/november/new-method-developed-to-3d-print-fully...
 
Description Soapbox Science 2020 - 18th September 2020 - Alice Konta 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Schools
Results and Impact PhD student Alice Konta submitted a video about her research and these were followed by live Q&A with the viewers who asked questions for 5-10 min.
Year(s) Of Engagement Activity 2020
 
Description University of Nottingham Faculty of Engineering Christmas Lecture - support activities 
Form Of Engagement Activity Participation in an activity, workshop or similar
Part Of Official Scheme? No
Geographic Reach Local
Primary Audience Schools
Results and Impact CfAM team members (Programme and Platform Grant)took part in the support engagement activities which form part of the UoN Faculty of Engineering Christmas Lecture for local school students.
Year(s) Of Engagement Activity 2019,2020
 
Description Workshop at the Royal Society (RH) 
Form Of Engagement Activity A formal working group, expert panel or dialogue
Part Of Official Scheme? No
Geographic Reach National
Primary Audience Industry/Business
Results and Impact In June 2017 Prof Richard Hague was invited to the Emerging technologies and economy workshop at the Royal Society
Year(s) Of Engagement Activity 2017