Series production of Lightweight parts by Isostatic pressing of Metal powders to give Material and Energy Reduction (SLIMMER)

A novel, sequential, net-shape process will be developed to enable complex, light-weight components to be created with minimum waste capable of supporting a wide range of production volumes. Metal powders are encapsulated in a complex-geometry reusable rubber tool and isostatically pressed. The resulting compacts are fully densified using a novel hot isostatic pressing (HIP) method that enables the densification of multiple green compacts into full density. Key innovations include novel tooling method to produce partially consolidated complex compacts and novel processing route to simultaneously consolidate multiple components to full density.

Scientific / Technological / Economic benefits for companies
The immediate benefits are likely to be directly to the industrial end-users is the capability to use a novel manufacturing
process (bran tub), which generates lighter structures, with low cost tooling, and maximum material usage efficiency. In
addition, the activity based at UoB will provide the industrial end-users with computational modelling tools that minimise the
number of trials and iterations required to achieve the desired product quality and performance. The modelling tool will be
underpinned by sufficient scientific foundations, while making it flexible to be applied in an industrial context. Finally indirect
benefits are expected for a wider set of companies in the metals and ceramic processing sectors. This includes general
powder metallurgy, ceramics sintering, diffusion bonding, hot Isostatic pressing, powder injection moulding, etc... This may
well be through academic partners or catapult centres, which is one reason for wanting to publicise the research through
conferences that will attract both academic and industrial attendees.

Employment
The longer term benefits will be indirectly to the employees of the end-users, the university, and the UK supply chain (e.g.
powders, tooling, HIPping providers). This will help safeguard 100s of job opportunities across the UK. It will also generate
wealth through the development of new processes and products.

Society
The wider impact of this project on the society will be mainly focused on the reduction of material waste, energy usage, and
carbon footprint of manufacturing. The use of netshape powder processing will replace the conventional subtractive
manufacturing technologies, which are energy-intensive and result in material waste that can sometimes be difficult to
recycle. In addition, the reduction of the number of operations will also reduce the energy required for manufacturing.
Furthermore, the development of lightweight structures, specifically in the transport sector, will result in lower fuel
consumption and will reduce the carbon footprint of the transport sector overall.

Individuals
The project will also develop the skills of the future leaders in manufacturing research, by training 2 junior academics.