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The impact presented in this case study is the commercialisation of 15 products with perfume microcapsules by Procter and Gamble (P&G), made possible using capsule mechanical strength data provided by Prof Zhibing Zhang's research group at Birmingham. Use of microcapsules gives improved freshness performance, and thus commercial advantage, compared with traditional formulations; they have been incorporated in P&G's four major billion-dollar brands — Downy, Febreze, Lenor and Tide. This has significantly improved their competitiveness enabling P&G to retain their leading position in the USA and Western Europe. A novel micromanipulation technique developed at the University of Birmingham has been used extensively to obtain mechanical properties data for the micro-particles, including microcapsules prepared in Birmingham and provided by companies, which is related to their formulation and processing conditions and end- use performance. In addition, the knowledge generated has helped 15 other companies to commercialise new functional products containing micro-particles.
The Computational Mechanics and Reliability Group at the University of Greenwich has been developing computational methods for predicting material behaviour and component reliability since the late 1990s. This case study details economic and environmental impacts and impacts on practitioners. In particular it shows how our expertise has:
The development of unique computer simulation tools has profoundly influenced the design and manufacture of silicon chips fuelling the $300 billion per year semiconductor industry. A pioneer of statistical variability research, Professor Asen Asenov developed understanding and awareness of statistical variability in the nanoscale transistors which make up all silicon chips. Gold Standard Simulations (GSS) was created in 2010 and by 2012-13 had grown revenue from services and licensing to $1million. GSS tools are currently used in foundries providing 75% of all semiconductor production for fabless design companies globally. For example, working with GSS and their simulation tools has reduced the development time for IBM's next generation of CMOS technology by 1 year, representing significant savings in the 3-5 year technology development cycle.
Optimisation tools developed in the UoA have significantly advanced the ability to find the best designs for complex systems in cases where these were previously unobtainable. These optimisation tools have been implemented in several companies to shorten design times, reduce costs and reduce CO2 emissions. This has brought about new multi-million pound revenues, long-term contracts, increased employment and contribution to sustainability targets.
Research undertaken in the University of Cambridge Department of Physics has provided benchmark data on, and fundamental physical insights into, the high strain-rate response of materials, including powdered reactive metal compositions. The data have been used widely by QinetiQ plc. to support numerical modelling and product development in important industrial and defence applications. One outcome has been the development of a reactive metal perforator for the oil industry which significantly outperforms conventional devices. These devices `perforate' the region around a bore-hole, thereby substantially enhancing recovery, particularly in more difficult oil fields, and extending their economic viability. Over a million perforators have been deployed since their introduction in 2007.
Research into variable mechanical energy absorption, using Finite Element (FE) modelling and analysis, funded by Cellbond Ltd., led to a design specification for an Offset Deformable Barrier (ODB). Such barriers are used within the motor manufacturing industry to test vehicular safety. Based on the findings of our research, the barrier used in car crash tests has been redesigned. The design specification for the barrier has been adopted by the European New Car Assessment Programme (EuroNCAP). All newly designed cars are tested with this type of barrier before they enter production. The use of FE modelling and virtual crash testing allows barriers to be designed with particular properties and for the crash testing cycle to be shortened.
Dr Richard Brooks and his team at the University of Nottingham have been investigating the high strain rate behaviour of composite materials since 2003. This has led to the development of two products that are being installed in streets in the UK and Ireland by East Midlands SME Frangible Safety Posts Ltd. The direct benefits to the company have been: the installation of 900 products in the UK and Ireland; saving of £17k capital cost and 2 months in terms of time to market per product developed and; raising of £1.8M investment to bring the products to market At least one life has already been saved in the Shetland Islands as a direct consequence of the product behaving in the way it was designed to.
For aerospace vehicles, the development of new materials and structural configurations are key tools in the relentless drive to reduce weight and increase performance (in terms of, for example, speed and flight characteristics). The economic drivers are clear — it is widely recognised that it is worth approximately $10k to save one pound of weight in a spacecraft per launch and $500 per pound for an aircraft over its lifetime. The environmental drivers (ACARE 2050) are also clear — reduced aircraft weight leads to lower fuel burn and, in turn, to lower CO2 and NOx emissions. With such high cost-to-weight ratios, there is intense industrial interest in the development of new structural configurations/concepts and enhanced structural models that allow better use of existing or new materials. Analytical structural mechanics models of novel anisotropic structures, developed at the University's Advanced Composites Centre for Innovation and Science (ACCIS), are now used in the industrial design of aircraft and spacecraft. Based on this research, a new, unique anisotropic composite blade, designed to meet an Urgent Operational Requirement for the MoD, is now flying on AgustaWestland EH101 helicopters that are deployed in Theatre. In addition, the new modelling tools and techniques have been adopted by Airbus, AgustaWestland, Cassidian and NASA and incorporated into LUSAS's finite element analysis software. These tools have, for example, been used to inform Airbus's decision to use a largely aluminium wing design rather than a hybrid CFRP/aluminium wing for the A380.
Raman thermography, a new technique for measuring channel temperature in semiconductor electronic devices developed at the University of Bristol, has been used by many companies to characterise their semiconductor devices. The technology has enabled companies to develop more robust, reliable, higher performing devices and circuits for high-end space, radar, communication and power conversion applications. This is illustrated here in detail on the example of the company, United Monolithic Semiconductor (UMS) (Germany-France), which used the technique to improve the lifetime of its Gallium Nitride (GaN) and Gallium Arsenide (GaAs) semiconductor devices so that they meet customer requirements for product qualification. Corresponding impact resulted for the companies TriQuint (USA), Northrup Grumman (USA), QinetiQ (UK), Selex Galileo (UK & Italy), NXP (UK & Netherlands), Thales Alenia Spaciale (France), Sharp (Japan) and Hitachi Cable (Japan).
Researchers within the Department of Physics and Astronomy at UCL have investigated the properties of defects in bulk HfO2 and at Si/SiOx/HfO2 interfaces. Results have been used by an industrial partner, SEMATECH (SMT), to improve the quality and reliability of high-performance microelectronic devices based on transistors. This has helped SMT to meet project objectives on behalf of member companies such as Intel and IBM, and UCL research results have been consistently highly evaluated by these companies. Recommendations made by SMT have been implemented by industrial partners in their currently manufactured devices, such as the 22nm process technology released by Intel in 2011.