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The development of disentangled, ultrahigh molecular weight polyethylene at Loughborough University since January 2007 has provided an environmental friendly route to the manufacture of high modulus, high tensile strength tapes with applications ranging from body armour to helmets, ropes and cables. Commercialisation is being undertaken by the Japanese company Teijin, in the Netherlands, under the brand name Endumax®. The new business, started in 2011, now employs >80 staff and predicts annual sales of >€15M from 2014 with an increase of ~10% over the first five years. Competitors such as Du Pont (Tensylon®) and DSM (Dyneema BT10®) have also initiated development of products using the new process route.
Workers at the University of Leeds researched, then developed and patented the `hot compaction' process for the manufacture of single polymer composites [1]. In this process highly oriented polymer fibres are heated so that a proportion of the surface of every oriented element melts. Upon cooling, this skin recrystallises to form the matrix of a self-reinforced fibre composite. Important resultant properties include high stiffness and strength, lightweight and outstanding impact strength, leading to a material with crucial commercial advantage. The reach of this impact is demonstrated by commercialisation of the polymer composite over a wide range of applications including anti-ballistic body armour, sports goods (Nike, Bauer), lightweight luggage (Samsonite), audio speakers (Wharfedale) and radar covers for helicopters (Westland). Examples include Samsonite using the material Curv® to manufacture two new high profile product ranges (Cosmolite and Cubelite) and Bauer using it in their elite-level ice hockey skate range (SUPREME and VAPOR).
The Thin Film Centre (TFC) group at UWS pioneered thin film materials and processes for plastic electronics with Dupont Teijin Films (DTF) Ltd and Plastic Logic (PL) Ltd over a period of nine years. This work was pivotal to the growth of PL from a start-up position resulting in the first all-polymer e-book reader and was the basis of a world leading position in the supply of specialised substrates for DTF Ltd.
Research into die drawing of polymers at Bradford has resulted in a new building material that is stronger and more durable than wood; and new bioresorbable shape-memory polymers for use in medical implants that reduce patient trauma and costs. The wood replacement material is commercialised by the United Forest Products/Dow USA 2010 spin out company Eovations LLC for use in a range of construction applications; the bioresorbable shape-memory polymers have recently been patented (4 patents filed) by Smith & Nephew for use in soft tissue fixations. These impacts form part of a range of exploitations of our oriented polymer technology.
Research undertaken by the University of Sheffield between 1999 and 2012 in functional oxide thin films was commercialised through knowledge transfer partnerships (KTP) with Ilika Technology. This directly led to over £1M in contracts and subsequent improvements in the commercial viability of the product base of blue-chip companies such as Toshiba, Toyota and Ceramtec and contributed to the increase in Ilika's turnover to ~£2M per annum and a growth in staff from 5 to 35 in 2012. In 2011, Ilika floated on the stock exchange with a valuation of ~£20M. The CEO has personally recognised the role Sheffield has played in establishing Ilika Technology as a limited company and in growing company revenue through contracts with leading multinationals.
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.
Research carried out by Prof. Ton Peijs and colleagues has led to significant breakthroughs in engineering plastics: PURE® and its licensed Tegris® technology, which are lightweight self- reinforced alternatives to traditional polypropylene (PP) composites such as glass-fibre or natural- fibre-reinforced PP. Environmentally friendly and 100% recyclable, these strong and ultra-light self- reinforced plastics have been successfully used across a number of applications, from suitcases and sports gear to protective armour and automotive panels, with impressive results. When used for car, truck and van components, they have been shown to help lower exhaust emission levels and increase fuel economy.
Novel vapour sorption experimental methods for the characterisation of complex particulate materials have been developed in the Department of Chemical Engineering. This research and expertise resulted in the creation of Surface Measurement Systems Limited (SMS), whose Dynamic Vapour Sorption (DVS) and Inverse Gas Chromatography (IGC) instruments are now found in >500 laboratories around the world. They are recognised standard research and development tools in the global pharmaceutical industry (DIN 66138). SMS has contributed >270 man-years of employment and generated £27M of turnover, whilst SMS instruments have generated over £300M of economic value, over the REF period.
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.
Research in the Mechanical Engineering Department has led to a series of experimental techniques for measuring the fundamental properties of lubricants in a scientific manner. These include measurement of the thickness, structure and properties of fluid and solid lubricating films, as well as the friction, fatigue and wear behaviour of lubricated surfaces.
Measuring instruments based upon these techniques have been commercialised by a spin-out company, PCS Instruments, which has now become the largest supplier of Tribology test equipment in the world. Over the period 2008-13 it had a turnover of £39.8M (£7.63M in 2012-13). The research has changed the way in which lubricants and lubricant additives are developed, with PCS test rigs in use in all the major lubricant and additive companies, as well as many University tribology research and National Standards laboratories. The techniques have enabled the development by industry of a new generation of high-efficiency lubricants for automotive applications.