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The A350-XWB is the first Airbus airliner to have composite wings, thereby reducing structural weight compared with the current generation of metallic wings. With over 700 orders for the aircraft, the company has placed great emphasis on the need to maximise performance benefits whilst mitigating risk associated with manufacture of the all-new wing. The Bath Composites Research Unit has supplied underpinning research to:
(1) Develop an algorithm that has been used to design the composite wing skins for optimised performance;
(2) Analyse the laminate consolidation process for the wing spars.
The impact of (1) is a direct saving of 1.0 tonne of fuel per typical flight compared with current metallic skins. This represents a total fuel saving of around 40,000 tonnes, over the design life of each aircraft. The impact of (2) is the achievement of satisfactory part quality for current production rates of spars valued at £1M each when equipped.
Diffusion bonding (DB) is well-known for producing structured materials with fine scale features and is a critical technology for high efficiency reactors, e.g. heat exchangers and fuel cells, but currently equipment is slow and expensive (and there are size limitations to the `assemblies' that can be built). The University has researched and developed, with industry partners, a rapid affordable diffusion bonding (ADB) process involving direct heating to provide appropriate temperature and stress states and utilising flexible ultra-insulation (vacuum) for pressing titanium (and now aluminium) sheets together. The process operates at low stresses thus avoiding `channel' collapse. Investment is taking place in the partner companies to exploit the technology. A breakthrough has been achieved in the chemical machining of three dimensional structures for laminar flow technology assemblies in aluminium and titanium, that can be built by ADB.
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.
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.
The investigators of this impact case study have utilised their expertise in materials engineering, theoretical/numerical modelling and product development to achieve significant economic, social and environmental impacts in a range of fields through developing a systematic methodology for innovative product design and optimisation. Through several industrial projects and collaborations, significant impacts have been witnessed including new products creating several million pounds in revenue annually for businesses in different sectors and green manufacturing technologies in repair and reclamation of components. All the described impacts were results of investigation in the Mechanical Engineering and Materials Research Centre (MEMARC) over the assessment period.
University of Bradford research has enabled a material manufacturing company, Armacell, to reuse up to 95% of its production waste to produce new, high-value acoustic products with up to 50% better acoustic performance than any competition products of similar size. We protected the developed IP through several international patents and set up a spin-off company, Acoutechs Ltd, to explore this technology commercially. These materials are now used to reduce noise levels below the recommended limits and to improve the general acoustic quality of spaces at home and work for the benefit of public health. The products generate an annual turnover of more than €4 million for Armacell and prevent more than 500 tonnes of plastic waste from going into landfill annually.
Research at Manchester has led to the development of a new class of high performance magnesium alloys based on the addition of rare-earth alloying elements. The new alloys combine low density and the highest strength of any magnesium alloy. Used to substitute for aluminium in aerospace and automotive they produce weight savings of 35% improving performance and reducing fuel consumption. Commercialisation of these alloys by Magnesium Elektron (ME), the international leader in magnesium alloy development, contributes over $20m per annum to company revenue. This includes development of the first commercial product available for bioresorbable magnesium implants, SynermagTM, launched in 2012.
BRITEST is a global leader in the development of innovative process solutions for the chemical processing sector with > £500m of value being realized since 2008. Research in Manchester (1997-2000) generated a set of novel tools and methodologies which analyse chemical processes to identify where and how process improvements could be made. BRITEST was established in 2001 as a not-for-profit company to manage the technology transfer and effective deployment of these tools and methodologies into industry. Manchester holds the IP arising from the underpinning research and has granted an exclusive license to BRITEST for use and exploitation of the toolkit.
UCL's creation of ultra scale-down (USD) technologies has led to economic benefits by speeding to manufacture next-generation healthcare products. This has resulted in documented savings for pharmaceutical companies in pilot-scale studies (eg ~£280k for a protein therapy) and in manufacturing cost-of-goods (eg ~£200k pa for an antibody). Licensing values realised for USD-facilitated manufacturing processes range from a £10m early-stage payment for an antibody therapy [text removed for publication] to US$1bn for a therapeutic vaccine.
Since 2008 some 40 companies have used UCL USD technologies, which have now also facilitated the formation of a spin-out company and additional job creation. Patient benefits have emerged through the contribution of USD to better bioprocess definition, with USD technologies now helping deliver the US Food and Drug Administration's Quality by Design initiative for biopharmaceuticals, valued at more than US$20bn a year through a 25% reduction in time-to-market and more robust manufacture.
Driven by concerns over public health and intensifying legislative demands of the food industry in Europe and USA, the reliable and effective removal of unwanted objects from food products at a processing stage is increasingly important. The assurance of food quality and safety throughout the pre- and post-harvest food chain makes this issue even more significant. The effective implementation of relevant technological solutions for food safety and quality can dictate the survival, growth and competitive edge of some major sectors of the economy.
Food sorting machines are essential for eliminating unwanted food items from the production process to ensure that quality is maintained at the highest level for consumers. Key research at City University London has led to the development of a unique solenoid actuator valve (ejector), which opens and closes a high-pressure air jet in such machines to remove defective food items more accurately and efficiently from the production line.
The sorting machines which use it have a fivefold improvement in consumer food quality and safety and are 20% more energy efficient. Sales of these machines have been enhanced by 50% as a consequence of these improvements. The new valve delivers approximately 50% less food waste during the first sorting pass and offers a fourfold reduction in power consumption, contributing positively to global agricultural sustainability. The work undertaken has also assisted the industrial partner in opening up a new market for sorting machines for sorting plastics.