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This case study deals with research undertaken at Plymouth University leading to the development of an innovative friction stir welding process (friction hydro-taper pillar processing, FHPP) and a bespoke welding platform that improves the assessment and repair methodology for creep damaged thermal power station components. This technology, developed in collaboration with Nelson Mandela Metropolitan University and with industry investment, enables power station engineers to extend the life of power generating plant leading to multi-million pound cost savings (over £66M in direct financial savings are demonstrated in this case) plus significant safety and societal impacts. It has been patented in South Africa and a spin-off company has been formed.
Please note that economic impact values were achieved in Rand (R) but are expressed in £ and therefore worth less in £ today than during the period when the stated impact was achieved.
This case study is based on research and impact of the development of creative systems and creative systems management to enhance professional in-house design capabilities of design and manufacturing companies through the use of new technologies. The research was conducted by Dave Henley and Rob Cooksey over the duration of several years (2008-2012) to develop the transferable application of design systems and management for SMEs. The research included three different Knowledge Transfer Partnerships (KTPs) with Fairfield Displays & Lighting Ltd., China Industries Ltd., and Tough Furniture Ltd. The research evidences impact in the development of the companies' creative capabilities through significant increases in turnover, employment and market penetration and a number of awards, as well as in public benefits such as social inclusion, community health and well-being.
Researchers from this UoA developed 3D modelling techniques and virtual visualisation software to help car-makers address potential imperfections (gaps between panels, misalignments, etc) that arise during vehicle assembly, even when all part dimensions are manufactured to within their tolerance range. The University of Leeds spun out Icona Solutions in 2003 to develop and exploit this intellectual property. Icona's Aesthetica software was launched in 2006, and since 2008 it has been licensed by over 20 automotive companies in 10 countries. The software has contributed to improvements in the design and manufacture of around 70 different vehicle lines, reaching over 40 million consumers, and saving car-makers approximately £25 million in efficiency and cost savings (including reduced scrap and rectification costs). Icona's turnover since 2008 is well over £1 million.
Research by the Jewellery Industry Innovation Centre (JIIC) has been influential in taking curation beyond normal museum practice. The work has led to the development of novel applications of digital scanning, CAD processes and rapid prototyping. These have enabled the creation of detailed replicas of damaged and deformed precious and fragile objects of cultural heritage. Coupled with the craft design expertise of the researchers these processes have shed new light on the techniques used to produce the original pieces. The handleable replicas that these processes generate are transforming the way museum curators are balancing the competing demands of preservation, restoration and interpretation of objects with those of public access to them. JIIC has assisted museum and heritage professionals at several venues with these transformative approaches, e.g. Black Country Living Museum, Birmingham Museums and Art Gallery (BMAG), the Museum of London and National Museums Liverpool.
Professor Stephen Russell's fundamental and applied research on the formation, structure and properties of nonwoven fabrics has directly led to the creation and continued success of the Nonwovens Innovation and Research Institute (NIRI) Ltd a University of Leeds spin-out company. Formed in 2005 to exploit Russell's research, NIRI has grown annual sales revenue to ~£1 million supplying products and services that have enabled many medium-sized enterprises (SMEs) and global public limited companies (PLCs) to launch improved or new products, growing their market share and positively impacting consumers. Additionally, the research has enabled NIRI to independently establish and co-fund new commercial joint ventures that have resulted in the development of new IP (intellectual property)-protected products for improving global health and security. NIRI has grown its workforce to twenty (mainly University graduates) and has been profitable from the first year of trading.
Heriot-Watt University (HWU) led the development of a supportive infrastructure for the sustainable advancement of Technical Textiles (the fastest growing textiles sector in an industry worth $25bn globally and £3bn per year to the UK economy). 452 companies have had their products or processes created or improved. (e.g. patents awarded, new companies established and research and development sustained). The research transformed how Technical Textiles were understood as marketable products in their own right; from purely functional entities to materials that operate at the interface of design and technology. This enabled the development of new technologies that enhance wellbeing and quality of life, e.g. in the health and defence sectors.
A manufacturing process developed by Bradford researchers has revolutionised the way endodontists perform root canal treatments. When coated with a hydrophilic polymer, the highly-filled hygroscopic material has enabled UK company DRFP to develop SmartPoint — a new endodontic technique that dramatically reduces failure rates of root canal treatments from 11-30% over five years to approximately 1%, and gives lower levels of post-operative pain when compared with conventional techniques. The technology has won three awards for innovation and DRFP has expanded significantly, with a dedicated production facility and sales team offering visits to dentists to demonstrate the benefits of the technology.
This research, performed in the Department of Mechanical Engineering at Sheffield, has provided a unique method for measuring oil films in real engineering components like ball-bearings, thrust pads, seals, and piston rings. Adopted by leading industrial customers across Europe, the resulting benefits include the development of new seal designs and piston ring-pack products as well as trouble-shooting pump failure. The spin-out company, Tribosonics Ltd., which manufactures the instrumentation under licence and provides consultancy services, currently employs eight people and turned over £450k in 2012 (£600k expected in 2013). Customers include [text removed for publication] who have seen their new ring pack reduce oil consumption by up to 40%, saving $160K per year per engine and [text removed for publication] whose seals designed and tested using our methods have 10% of the leakage of conventional seals.
This case study is about the development of flame retardant (FR) polypropylene yarns used in upholstery fabrics for domestic and office furniture, automotive and floor coverings that will have predictable and reproducible fire retardant properties when subjected to standard testing procedures. Through the UK DTI funded project FLAMTECH (2002-2005) shared by Camira Fabrics Ltd., and the university, a range of novel polypropylene yarns having higher levels of consistent fire performance than the previously existing products in the market place were developed. A testing protocol which could establish individual fibre/yarn/fabric structural-fire property relationships and correlate these with (and hence predict) final fabric performance was also established. The project overlapped a concurrent EPSRC funded research in which nanocomposite fibres (including polypropylene) with improved flame retardancy and reduced melt dripping were developed. Camira were also members of the consortium managing this project. The major commercial outcome from these projects since 2005 is a flame retardant polypropylene product being marketed by Camira fabrics within their Perfentex brand and others are also being considered. This work also inspired the Production Director of Camira Fabrics to register at Bolton as a PhD-by-publication candidate and hence gain more knowledge about the subject area, as evidenced by the publication of her research papers (see Paper 1, Section 3).
Research at the University of Manchester has supported the development of inertia and linear friction welding of high temperature materials for aeroengine application. The research has guided process parameter development and led to deployment of these new welding techniques at Rolls-Royce plc. In particular, inertia friction welding is now used in modern gas turbine engines, such as the Trent 900, which powers the A380, Trent 1000 for the Boeing 787 and Trent XWB for the Airbus A350. In addition, research has enabled blisk technology (welding of blades on disks), which has delivered up to 30% weight saving on critical rotating components.