EPSRC Centre for Innovative Manufacturing in Ultra Precision
Lead Research Organisation:
CRANFIELD UNIVERSITY
Department Name: School of Water, Energy and Environment
Abstract
Many high value next generation products demand macro scale ultra precision components, with micro-scale structure possessing nanometric tolerance. CIM-UP's vision is to be the world's foremost research centre for innovation in next generation ultra-precision production systems and products with global outreach. It will foster and accelerate development of emerging high value products through its dedicated production compatible ultra precision process research platforms and internationally leading research programme. It will facilitate the engagement of the UK precision manufacturing supply chain into the future wealth creating opportunities of emerging sectors.The key manufacturing challenges that will be met by CIM-UP are the creation of a suite of ultra-high precision closed loop (integrated metrology) digital based manufacturing tools that offer a step-change in the fabrication routes for products that require nanoscale precision across length scales from nm to several metres.It is intended that process research will extend energy processing technologies, such as plasmas, lasers, ion and electron beams, and low temperature deposition techniques into fully capable ultra precision manufacturing processes. It is intended these emergent processes will be employed sequentially or simultaneously with established ultra precision processes within newly devised research platforms. These research platforms will be created in partnership with suitable UK industrial partners using a fully digital mechatronic design process. The design processes will extend; CAD, FEA (thermal/dynamic), CAM and performance verification using modal techniques for thermal and mechanical structural analyses. Performance verification will be undertaken using internationally accepted test procedures that will be verified, and where necessary enhanced, using the services of an appropriate national laboratory.Important UK manufacturing operations within biomedical, telecommunications, energy generation, aerospace/space, transport, pharmaceutical and future display technologies rely on precision engineering. Emerging fields of printed electronics and flexible displays are highly dependent on the creation of new production capabilities which will need to offer step changes in precision accuracy and productivity. The overarching aim of CIM-UP will be to realise research processes and platforms that define a new generation of rapid and effective ultra precision production systems. In this way, this centre will reconcile the simultaneous demands of 'accuracy' and 'rapid production capacity' thereby establishing advanced manufacturing technologies pivotal to important emerging market sectors. Through close interaction with the UK's precision manufacturing technology supply chain and product end users/developers, a unique world-leading ultra precision research centre will be established by two internationally recognised research institutes. This collaborative application builds on previous research programme partnerships established through earlier IMRC activities, Grand Challenges and the UPS2 Integrated Knowledge Centre. The UPS2 IKC and Cambridge CIKC will provide pipe-line translation mechanisms for the proposed early TRL research outputs from CIM-UP.
Planned Impact
The major beneficiaries on whom CIM-UP's research will impact include UK manufacturing companies (especially SMEs) the University partners and society in general. Benefits will be realised in terms of the economy, knowledge and people. The importance of manufacturing to the UK economy and the key issues and barriers to economic success are highlighted in the main proposal which demonstrate the central role of manufacturing technology in ensuring economic growth. Many emerging sectors and next generation products will demand large-scale ultra precision (nanometre-level tolerance) complex components. To date numerous discrete process steps have evolved into long process chains requiring high levels of capital investment. Such extensive process chains are needed to create even initial pre-production prototypes. This issue has become a significant barrier to SME's realising their innovative products. Since it is widely acknowledged that manufacturing employment growth will stem from SMEs and emerging sectors, this issue is of national importance. The UK holds a world-leading position in ultra precision related manufacturing research, which has in recent years gained highly effective and unique ultra precision R&D infrastructure operating beyond those established industrial sectors such as aerospace, automotive and defence. Therefore, opportunities exist to leverage UK precision manufacturing supply chain organisations towards identified emerging sectors where, in partnership with leading UK researchers, a unique potential for greater wealth generation can be realised for the UK from its innovation capacity. This potential is currently unaddressed and requires a distinctive approach focused on Ultra Precision manufacturing. This is the opportunity and challenge for the CIM-UP. Manufacturing success requires the generation of new knowledge and innovation. In particular, business requires new, innovative ideas that can become reality. The research focus of CIM-UP will target key areas of manufacturing technology that will be developed in partnership between the Centre and the industrial partners. This leading edge research will support both the industrial and University strategies and in addition contribute to the broader UK national need. To realise this future success, manufacturing requires leaders with both the knowledge and vision to grow UK manufacturing business. CIM-UP will produce individuals who will provide such leadership to ensure that UK manufacturing can meet the future technical and business challenges needed to compete globally. The potential of the UK's innovation capacity to create new high-end manufacturing jobs is significant. Maximising this wealth generation opportunity within the UK will however depend on successfully realising next generation innovative production systems. Without relevant production research, r&d infrastructure, and an effective technology supply chain, there will be a limit to the UK's direct employment growth from its innovation capacity, leading to a constant migration of UK wealth creation potential into overseas economies. CIM-UP will develop a significant number of highly trained manufacturing engineers who will be essential to provide the leadership necessary to drive UK high value manufacturing forward and provide the vision for future prosperity. Manufacturing business requires people who can generate knowledge and then transform that knowledge into action. CIM-UP will provide researchers with the breadth of skills, both technical and business, to make a real impact on the future of UK manufacturing.
Organisations
- CRANFIELD UNIVERSITY (Lead Research Organisation)
- FANUC UK (Collaboration)
- Qioptic (Collaboration)
- Gooch & Housego (United Kingdom) (Project Partner)
- National Physical Laboratory (Project Partner)
- Fives Landis (United Kingdom) (Project Partner)
- Microsharp (United Kingdom) (Project Partner)
- Hexagon (United Kingdom) (Project Partner)
- TRUMPF (United Kingdom) (Project Partner)
- M-Solv (United Kingdom) (Project Partner)
Publications
Gordon GS
(2015)
Single-pixel phase-corrected fiber bundle endomicroscopy with lensless focussing capability.
in Journal of lightwave technology : a joint IEEE/OSA publication
Hallam T
(2014)
Field emission characteristics of contact printed graphene fins.
in Small (Weinheim an der Bergstrasse, Germany)
Han J
(2014)
Shaping the Optical Fibre Output Beam by Focussed Ion Beam Machining of Phase Hologram on Fibre Tip
in Proceedings of the 14th International Conference of euspen, 2014
Henning A
(2013)
Correction for lateral distortion in coherence scanning interferometry
in CIRP Annals
Hughes B
(2011)
Laser tracker error determination using a network measurement
in Measurement Science and Technology
Hyman R
(2015)
Phase modulation using different orientations of a chiral nematic in liquid crystal over silicon devices
in Liquid Crystals
Jhen-Si Chen J
(2017)
Minimizing the effects of unmodulated light and uneven intensity profile on the holographic images reconstructed by pixelated spatial light modulators Minimizing the effects of unmodulated light and uneven intensity profile on the holographic images reconstructed by pixelated spatial light modulators
in Chinese Optics Letters
Jonathon Parkins (Author)
(2012)
Laser Assisted Plasma Processing: an overview
Description | The overarching technical challenge of this centre is to be able to fabricate tiny features and rapidly apply them to very large scale surfaces. Added to that is the complication that the large areas might be plastic films that change shape during processing. Thus far, the centre has engaged numerous UK (and some international) companies into this engineering challenge. Promising results in regards facilities and capability development have been achieved at this half term position. |
Exploitation Route | Research platforms have been created. New techniques for Ultra Precision Manufacturing have been established. One of three research platforms is a commercial product being exploited through Cranfield spin out. A second research platform represents the UK's leading research facility for reel to reel processing of films. This research platform is being employed by the CDT in Ultra Precision. A third research platform held at Cambridge is also being used as the UK's Precision Laser Processing System. This third system is also being employed by researchers involved with EPRSC in Ultra Precision. |
Sectors | Aerospace Defence and Marine Education Electronics Environment Healthcare Manufacturing including Industrial Biotechology |
URL | http://www.ultraprecision.org |
Description | Established 3 spin out companies Loxham Precision Laser Technologies UPS2 |
First Year Of Impact | 2011 |
Sector | Aerospace, Defence and Marine,Education,Electronics,Energy,Manufacturing, including Industrial Biotechology,Retail,Transport |
Impact Types | Societal Economic |
Description | Automated micro-ECM for Air Bearing Production |
Amount | £185,000 (GBP) |
Funding ID | Project 133269 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 12/2017 |
End | 12/2018 |
Description | EPSRC Centre for Doctoral Training in Ultra Precision |
Amount | £5,000,000 (GBP) |
Funding ID | EP/I015566/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 09/2011 |
End | 08/2022 |
Description | Impact Accelleration Account - Watch It Made |
Amount | £35,000 (GBP) |
Funding ID | Impact Accelleration Scheme |
Organisation | Cranfield University |
Sector | Academic/University |
Country | United Kingdom |
Start | 08/2014 |
End | 03/2015 |
Description | TSB Enhancing manufacturing through automation programme |
Amount | £646,875 (GBP) |
Funding ID | 101541 |
Organisation | Innovate UK |
Sector | Public |
Country | United Kingdom |
Start | 09/2013 |
End | 08/2016 |
Description | Automation of Advanced Optics Production |
Organisation | Qioptic |
Country | Germany |
Sector | Private |
PI Contribution | Partnership projects have led to a TSB funded project. New UK designed and built machines are to be tested in the UK's leading optics manufacturing system at Qioptiq |
Collaborator Contribution | Developed machine concepts for next generation diamond turning machines for the production of advanced IR optics |
Impact | TSB project #101541 Automation for mass production of high performance optics |
Description | Control systems and robot collaboration |
Organisation | FANUC UK |
Country | United Kingdom |
Sector | Private |
PI Contribution | Using Fanuc systems in research and MSc projects. Resulting in training/awareness of latest Fanuc products amongst young engineers. |
Collaborator Contribution | Utilisation of Fanuc products for dealing with major technical challenges in large science projects |
Impact | Control technology for large optics processing systems |
Title | Micro four compact machine design |
Description | Machine design licence to Loxham Precision ltd. |
IP Reference | |
Protection | Protection not required |
Year Protection Granted | 2014 |
Licensed | Yes |
Impact | Initial sales of machine secured. |
Title | BoX ultra precision grinding machine |
Description | High precision production grinding machine |
Type Of Technology | Systems, Materials & Instrumental Engineering |
Year Produced | 2008 |
Impact | Spin out company and licence deal |
URL | http://www.loxhamprecision.com/products/box-freeform-grinding-machine.html |
Title | Micro 4 - DTM |
Description | Compact ultra precision diamond turning machine tool |
Type Of Technology | Systems, Materials & Instrumental Engineering |
Year Produced | 2010 |
Impact | Product of spin out company TSB project #101541 |
URL | http://www.loxhamprecision.com/products/u4-turn-diamond-turning-machine.html |
Title | Micro 4 - micro mill |
Description | Compact ultra precision micro-milling machine tool |
Type Of Technology | Systems, Materials & Instrumental Engineering |
Year Produced | 2010 |
Impact | Product for spin out company |
URL | http://www.loxhamprecision.com/products/u4-micro-milling-turning-machine.html |
Title | Watch It Made |
Description | Engineering educational experience to enthuse children into the engineering profession |
Type Of Technology | New/Improved Technique/Technology |
Year Produced | 2013 |
Impact | Establishment of a Manufacturing Learning Studio that is intended to be the basis of a Franchise business putting engineering /manufacturing into the retail environment whilst giving children an experience to have pride in producing a quality product: a self designed watch. |
URL | http://watchitmade.org/ |
Title | mK ultra precision temperature controller |
Description | milli Kelvin temperature control system product for ultra precision thermal control demands |
Type Of Technology | Systems, Materials & Instrumental Engineering |
Year Produced | 2007 |
Impact | Spin out company product produced across two UK companies |
URL | http://www.loxhamprecision.com/products/mk-ultra-precision-temperature-controllers.html |
Company Name | Loxham Precision |
Description | Loxham Precision manufactures high precision machines and digital motion systems. |
Year Established | 2000 |
Impact | Secured contracts during its first year with a major optics company. In its second year it secured investment and is building a new machine tool. It also has secured funding via the TSB advanced automation programs. |
Website | http://www.loxhamprecision.com |
Company Name | Ultra Precision Structured Surfaces (UPS2) Ltd |
Description | |
Year Established | 2015 |
Impact | Sales Ultra Precision rolls to the global market. |
Website | http://www.ups2.co.uk |
Description | London International Youth Science Forum |
Form Of Engagement Activity | Participation in an open day or visit at my research institution |
Part Of Official Scheme? | Yes |
Geographic Reach | International |
Primary Audience | Other academic audiences (collaborators, peers etc.) |
Results and Impact | Career questions from the international delegates enthuse by the engineering behind science programmes Questions from 17-21 year olds about the engineering professions related to large science programmes |
Year(s) Of Engagement Activity | 2012 |
URL | http://www.ultraprecision.org/wp-content/uploads/2014/06/EPSRC-Centre-in-UP-Annual-Report-12-13.pdf |
Description | Superheros or Engineering Scientists |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | Local |
Primary Audience | Schools |
Results and Impact | Enthusing children into the world of engineering by asking questions about Superhero. e.g. Was the hulk as superhero or a scientist? Is Ironman an Engineer? After my talk some children opted to have their workplacement within my laboratory. Some went on to study STEM at university. |
Year(s) Of Engagement Activity | 2009,2010,2011,2012,2013,2014 |
Description | Watch It Made |
Form Of Engagement Activity | Participation in an open day or visit at my research institution |
Part Of Official Scheme? | No |
Geographic Reach | National |
Primary Audience | Schools |
Results and Impact | Watch It Made is an educational engineering experience offered to school children within my research centre Enthuses children to think about selecting engineering at GCSE level |
Year(s) Of Engagement Activity | 2013,2014 |
URL | http://www.watchitmade.org |
Description | euspen Student Challenge |
Form Of Engagement Activity | Participation in an activity, workshop or similar |
Part Of Official Scheme? | Yes |
Geographic Reach | International |
Primary Audience | Postgraduate students |
Results and Impact | Broadens students horizons across the participants and forms a co-hort of leading Precision Engineering Students across Europe. Long term contacts formed between students and potential / actual employers |
Year(s) Of Engagement Activity | 2008,2009,2010,2011,2012,2013 |
URL | http://www.euspen.eu/OurEvents/euspenChallenge.aspx |