Advanced Freeform Generator

Freeform and micro/nano-structured functional surfaces underpin many next generation engineering products like novel optics (lenses/mirrors) used in astronomy, semiconductor manufacture, imaging and illumination systems in aerospace and automotive sectors, as well as various micro/nano-structured surface-enabled self-clearing/anti-icing products. There is a huge scientific 'push' and technology 'pull' for more adventurous surfaces with substantial functional advantages. However, due to the limitation of machining reliability and efficiency of current micro- and nano-manufacturing technologies, it remains challenging to make these products at a high-volume production scale. The need for the development of novel/improved manufacturing processes and future ISO standards for freeform and structured surfaces is now more urgent than ever.

A new, highly specialised, and exciting piece of equipment, the Nanotech650FGV2, has the potential to address this need. It possesses diamond turning and raster fly-cutting functions, fast-tool-servo and slow slide servo elements, and micro milling and grinding spindles. The acquisition of a Nanotech650FGV2 would significantly enhance the University of Huddersfield's Centre for Precision Technologies' (CPT's), and indeed the UK's, capability to generate more severe and advanced functional surfaces feeding into areas of novel optics, new surface functionalities and ultra-precision manufacture.

The proposed strategic equipment will enable breakthrough research on novel multi-freeform optics for disruptive embedded sensor/instruments, novel hierarchical patterned surfaces for functional orientated applications and GDT for complex surface manufacturing. The research programme will lead to a step-change in ultra-precision freeform manufacturing in terms of complexity of surface geometry and texture, new/improved machining technology on novel engineering materials, and in-depth understanding of structure, processing, dynamics and surface functionalities.

The major usage of the equipment will focus on the manufacturing of freeform and structured surfaces to address the EPSRC Future Metrology Hub's Grand Challenges in embedded metrology (where new complex optics are critical for miniaturised sensors/instruments, for example, multiple freeform surfaces in a single optical component allow simultaneous correction of light aberrations in sensors/instruments) and the Hub's Platform Research Programme in functional surfaces (for example, hierarchical structured surfaces will allow incorporation of multiple functions into a single surface morphology). It will also be widely used for CPT's research in on-machine technology development, surface integrity, tooling, in-line measurement and process control. To ensure maximum usage, the machine will be offered as a research platform for collaborative research projects, and as a demonstrator facility for short programmes (typically 1-3 days) of "pump-priming" experiments through an online booking system.

Furthermore, the capability of the Nanotech650FGV2 will open a new avenue for CPT to explore frontier technologies and allow fast prototyping/development of novel optical devices and subsystems. Prototypes derived from this equipment will be quickly demonstrated and validated by UK partners, e.g. Catapult centres and technology developers, industry end-users, through the Metrology Hub to UK industry. The knowledge created will help to develop national and international standards to rapidly support production of new high added value products like compact/minimized micro-objective systems and spectra instruments for wider embedded metrology applications in UK smart manufacturing. The research enabled by the Nanotech650Gv2 directly aligns with the UK Government's Industrial Strategy and EPSRC Manufacturing the Future theme to support high value manufacturing and deliver significant economic impact in the next 10-50 years.

Aside from the academic community, the strategic investment in the Nanotech650FGV2 will have wide impact on UK economy, society, people and knowledge transfer.

A recent independent review of industrial digitisation - 'Made Smarter Review' (October 2017) - set the vision for the UK to become 'a global industrial leader in creating, adopting and exporting advanced digital technologies' by 2030 (https://www.gov.uk/government/publications/made-smarter-review). The proposed Advanced Freeform Generator facility would make a significant contribution to realising this aspiration by (1) boosting the health, scope and capability of the research disciplines that underpin advanced digital manufacturing technologies and (2) fostering new academic-industrial relationships in frontier digital manufacturing. There are a broad range of industries and Catapult centres involved in high-precision manufacturing and many of their research and future products can be enhanced through the use of freeform and structured surfaces, for example, costs/energy (material saving, aircraft efficiency), environment (safe automobile, better lighting system), and health (better image systems, better functional implants). Economic impacts are expected for a wide range of UK manufacturers/end-users, as well as at technology development companies feeding into those supply chains. Short- to medium-term benefits will arise through increased competitiveness of UK companies to offer unique products, whilst longer term benefits will result from the economic advantage of such competitiveness.

The new products derived from the Nanotech650FGV2 enabled research outcomes will also bring positive societal impacts. The high machining reliability of the equipment will allow rapid prototyping of more ambitious designs for next generation products such as displays, sensors and instrumentation, medical imaging systems and therapy devices, optical devices and subsystems etc. These performance enhanced devices/products will promote the development of civilian industry (e.g. super quality cars, smart mobile phones) and improve quality of daily life (e.g. permanent bone implants and various healthcare devices).

Furthermore, the access arrangements outlined in the Case for Support will increase the pool of expertise relevant to the related facilities enabling next-generation applications to help solve manufacturing and measurement challenges in diverse fields. Innovation calls under the EPSRC Future Metrology Hub's flexible funding will be made available for freeform and structured surface research and technology innovation, to create new collaborative research programmes with industry to push UK future innovative products using freeform for wider applications. A batch of new scientists and engineers, especially early-stage postdoctoral and graduate researchers, will be trained in these projects and become vital assets to UK industry.

The research programme enabled by this equipment will make significant contributions to knowledge and understanding in: advanced manufacturing, materials science, nanoscience and nanotechnology, precision metrology and healthcare. The exploitation of fundamental knowledge in all these areas will help maintain the leading position for UK enterprise in future advanced manufacturing and new technology development and lead to the development of future ISO standards on freeform structured surfaces. This will help deliver the UK's international impact and enable the UK to be first-to-market with fully compliant products and thus propel the UK economy towards future growth. For example, the research on multi-freeform optics will support the development of more agile, flexible and responsive measurement technologies, accelerating the UK autonomous manufacturing system transformation and bringing a leading competitive edge to the UK's advances in future high value manufacturing.