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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.
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.
The automotive and aerospace industries are keen to reduce their environmental impact and so have looked to move to lightweight materials. This creates issues in terms of joining, using and disposing of dissimilar materials. Oxford Brookes has therefore worked with national and multi-national companies in the adhesive, materials, automotive and aerospace industries to try to solve these problems. This has resulted in high quality research publications, innovative test equipment, improved numerical methods, novel designs, design guidelines, manufacturing procedures, British Standards, patents, commercial products and further funding. The impact of the work has global safety, environmental and economic benefits with multi-national aerospace and automotive companies implementing the results in current developments.
Research at the University of Bradford has enabled many major vehicle and brake manufacturers to improve the design of their brakes and braking systems to increase customer satisfaction and sales, and reduce costs. Methods have been developed to predict the thermo-mechanical and dynamic performance of brakes and provide design improvements. Durable solutions have been developed for noisy brakes, which have reduced warranty costs for approximately ten international collaborating companies including Bentley, where a squeal noise from the front brakes of a new vehicle had prevented it from being released for production. Our research has been embedded into short courses, which have trained over 250 engineers since 2008 and is incorporated into Jaguar Land Rover's (JLR) professional training.
Runway stones thrown up by aircraft undercarriage wheels can cause considerable damage to the aircraft structure. A model of runway debris lofting developed at Imperial College has been used for the new A400M military transport aircraft, which Airbus reported was `absolutely needed' during the successful development of a nose wheel debris deflector [5. A]. This deflector dramatically reduces the incidence and severity of the runway debris impacts and the associated maintenance costs and downtime of the new aircraft. Airbus has received 174 orders to date for the A400M. An indication of the cost savings comes from the Hercules C130K, the predecessor of the A400M, which incurred costs of up to £1M for each aircraft on active service in Afghanistan for the repair of runway debris damage. This cost is now eliminated for the Airbus A400M aircraft.
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.
As 288,000 UK construction workers were estimated to have contracted vibration white finger and 170,000 had claimed compensation by 2011 this study relates to the design and development of a hand and arm vibration (HAVmeter) monitor by the ERPE Reactec student start-up company. This company initially focussed on optimisation of sweeping for curlers, contributing to team GB winning the 2002 Winter Olympic Gold medal. The current Reactec (HAVmeter) instrument measures and reports on vibration white finger, which potentially affects 5 million British workers.
The HAVmeter has sales in excess of £9M, over the 2008-2013 period, and is now in use by 45,000 construction workers. Reactec, with 23 employees and a turnover of ~£2.5M p.a., company innovation has been recognised with 4 industrial awards since 2009.
Research at Portsmouth has significantly improved the understanding of damage tolerance under creep-fatigue-oxidation conditions experienced in aero-engine components. The understanding has been developed through research on a new-generation disc materials including U720Li and RR1000, which have since been used in Rolls-Royce engines including Trent 900 in Airbus A380, Trent 1000 in Boeing 787 and the latest Trent for Airbus A350 XWB. These new materials have enabled aircraft to operate more efficiently at higher temperatures, with a major impact on CO2 emission and a significant impact on economy due to the new market opportunities and the reduction of operating costs.
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.
Cranfield's work on ethylene supplemented storage is now exploited in the supply chains to major supermarkets in the UK, including Waitrose and Tesco, reducing waste and avoiding volatility in supply for fresh food products such as onions and potatoes. By prolonging storage life by up to six weeks it is also having a positive impact on the UK's self-sufficiency in these products, displacing imports from overseas.
Complementary work has also led to commercial ethylene scrubbing technologies for packaging, which typically save around 50% of in-store waste and add two days to the product life for a range of fruit and vegetables. Such packing is now in use in most mainstream UK supermarkets, and in the USA where it has created a new export market for the manufacturer.