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Research in electronic textiles, described in five granted worldwide patents, is having impacts in the health, sports, defence and fashion sectors. The central impact claimed comprises bringing second generation electronic textiles into manufacture through knitted garments for older people for vital sign monitoring that have been commercialised by a spin-out company, SmartLife Technology Ltd, and the development of a conductive suit for the Ministry of Defence. Work in the unit has also underpinned the development of electrically heated gloves by EXO2 Ltd and a new test for a hip protector system based on an advanced 3D spacer structure by Baltex Ltd. Baltex Ltd and EXO2 Ltd also plan to use the technology to develop additional products.
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.
Ulster research groups in the fields of composites and metal forming have had a long-term and fruitful engagement with major industries such as Caterpillar (FG Wilson), Rolls Royce and Bombardier. Since 2008 this has resulted in new patented technologies, significant cost/performance improvement in manufacturing, the delivery of on-site industrial training, the formation of spin-out companies and the establishment of the £6m N. Ireland Advanced Composites and Engineering Centre with currently 10 member companies. In particular, Ulster research has been at the heart of patented Bombardier processes which underpinned their strategic entry into the commercial narrow body aircraft market which is worth $43billion per annum globally. The C Series wing programme, which utilises composites, employs 800 people directly in Belfast at full production, with a further 2,000 employed in the supply chain. As of today, Bombardier has global orders and commitments for 388 C Series aircraft, which include firm orders for 177 of the new airliner.
This case study focuses on three Science/Art collaborations Primitive Streak, Wonderland and Catalytic Clothing (CatClo) undertaken since 1997 by Professor Helen Storey. Storey's work is genuinely collaborative, spanning arts, sciences and new technology fields, and produces projects which illuminate aspects of science and well-being in ways that engage with the public, communicate complicated concepts, and demonstrate the potential of science in an innovative and accessible manner. The projects have reached huge audiences and have made a significant contribution to raising public awareness of science and issues faced by society.
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).
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.
Nanomaterials research at Ulster into materials including diamond-like carbon (DLC) ultra-thin films, carbon nanotubes (CNT), graphene, silicon and metal oxide nanoparticles has resulted in direct uptake by major industrial manufacturers and led to a directly quantifiable socio-economic impact via added value, improved efficiencies and cost-savings and has secured or increased the employment of skilled engineering staff. Examples of this impact since 2008 include ceramic nanoparticles research in partnership with AVX Ltd that resulted in improved production efficiency processes (up 20%) and higher quality devices (up 10%). [text removed for publication] Research into ultra-thin DLC films, funded by Seagate, has led to their incorporation into magnetic media. [text removed for publication] Our nanoparticle research has attracted a new spin-in company SiSaf Ltd. (2009) and by incorporating NIBEC's expertise in nanomaterials into its business plan, the company was able to grow to a valuation of £3.5m and employ 7 people in skilled technical positions.
Nanoforce Technology Ltd. is a spin-out company wholly owned by QMUL, active in the field of polymeric and ceramic materials. Bridging the gap between academic research and industrial applications, Nanoforce has done business with over 100 companies since 2008, providing the key research expertise and specialist facilities to enable the development of new materials and commercial products, including Sugru® a room temperature vulcanizing silicone rubber, Zelfo® a self-binding cellulose material, and BiotexTM a range of high-performance yarns, fabrics and pre- consolidated sheets based renewable resources such as PLA and natural flax fibres. Nanoforce has been promoting the development and commercialisation of spark plasma sintering (SPS) since 2006, which resulted in Kennametal recently opening the first commercial SPS facility in the UK to produce advanced ceramic armour. Nanoforce's clients have included large multi-nationals such as DSM, Dow Chemical, General Electric, SABIC, L'Oreal, Shell, Sibelco, governmental agencies such as Defence Science and Technology Laboratory (Dstl), and a large number of SME's.
Initial research into polymer nanocomposites and their formation took place at Strathclyde from 2000 - 2010. This was followed by a collaboration with the world's largest manufacturer of composite kitchen sinks, Carron Phoenix Limited, through a 6-year Knowledge Transfer Partnership (KTP) which resulted in a successful new production process of its high-end synthetic granite kitchen sinks. This led to £4 million of capital investment in new production facilities at their Falkirk site, enabling the company to sustain its leading position in the designer kitchen sink market and retain its workforce of over 400 employees in central Scotland, including the 170 workers in the composite sink division in Falkirk. Within the REF period, the research has led to the manufacture and sale of in excess of one million kitchen sinks, generating sales revenue in excess of over £50M and supporting the UK economy.
Prof Silver's research on the development of the technology to fabricate 3D electro-optic circuits via ink-jet and screen printing has provided a more sustainable solution to conventional back-lit posters (energy saving up to 75%) and printed displays. Due to the flexibility of the components (they can be printed in any shape or design) and low maintenance (battery operational), the technology has been commercially exploited by several industrial collaborators. Johnson Matthey have used Brunel research to gain knowledge of the market and supply chain, to sell silver and palladium nano-particles for ink-jet printing and to inform the investment of around £2M on R&D in this area. Intrinsiq Materials Ltd successfully marketed copper-based inks for ink-jet printing of ACEL displays, allowing the company to employ 22 additional staff. In addition, they have secured $4M of venture capital investment to develop the technology. Printed Electronics Ltd have secured £8.6M of investment to develop a high-volume supply chain for printed electronics, and have employed an additional 9 staff within the company. As a result of working with Brunel, Keeling and Walker have begun to sell ink that contains antimony-doped tin oxide nano-powders.