Functionally graded material - Electroformed component robotic manufacturing

In this project advanced robotics and automation are used to unlock an innovative manufacturing process. Ultima Forma has a patented technology using electro-deposition to manufacture metallic engineering components to net-shape, in a low energy, low waste process. The process allows microscopic layers of dissimilar metals to be deposited sequentially. The design of this multi-layered structure can control the properties of material across a wide range, accessing properties that are not available in conventional materials. Furthermore, the properties can be varied from place to place within a part to form a multi-functional component as a single entity. This disruptive technology is unique in the UK and presents a completely new approach to the design and manufacture of advanced engineering components.

Airbus Defence and Space, in collaboration with Ultima Forma have developed a multi-functional component that combines 6 existing components into a single entity. This component reduces the number of parts, saves weight and space and reduces assembly time, providing competitive advantage to Airbus in the US$2.14bn satellite waveguide market.

Ultima Forma have already established a small proof-of-concept robotic cell to demonstrate the concept. This project will build an advanced robotic cell at out new factory site in Basingstoke to automate the production of functionally graded waveguides in batches to the quality standards required by Airbus. The entire robotic electrodeposition process will be controlled using advanced automation to ensure repeatability and quality assurance of every part is attained throughout the production process.

The automated production process can be applied to other engineering problems, where the advantage of functionally grade materials can provide new solutions. For example, composite materials are increasingly used for light-weight structures (such as the wings on the A380 aircraft, and blades for off-shore wind farms). However, these composite materials are vulnerable to erosion damage from the environment. Metallic coatings on these composite materials can provide protection and extend the operating lifetime of these structures with significant reduction of carbon footprint. Examples to demonstrate the technology will be produced during the project and be promoted to our existing network and displayed at relevant trade shows as well as through a range of media channels.