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Research work in the University of Cambridge Department of Engineering (DoEng) created a formal methodology for eco-design, based on lifecycle thinking that can be implemented during product design. This methodology and supporting reference data have been commercialised by DoEng spin-off company, Granta Design Limited, within Granta's software solutions: for engineering and product design in industry, integrating with the CAD environment; and for materials education. These products are incorporated in software suites that have over 200,000 users. Industry case studies demonstrate their value to end customers.
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.
Following the North Sea Piper Alpha oil rig accident in 1988 and subsequent Cullen inquiry, new and safer maintenance procedures were introduced. One of the most significant changes was the restriction in the use of welding repairs (hot work) in the maintenance of plant and pipework due to the risk of fire and explosion. Research at Newcastle provided a novel engineering model that formed the basis for implementation of a new repair technology. This used fibre reinforced polymer wraps to restore the integrity of pipes without `hot work' or any interruption of production, thus minimising operational costs and increasing worker safety. This new technology has now become industry standard with new ISO and ASME standards for pipeline repair established as mandatory standards in 2006 and 2008 respectively (ISO/TS 24817 — Composite repairs for pipework; and ASME PCC-2, Repair of pressure vessels and piping). The period 2008-2013 has seen considerable expansion, worldwide, of an industry offering materials and support services to enable composite repairs to be designed and carried out.
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.
The key impact is in the definition of best practice for the design of joints, components and structures comprised of glass fibre reinforced polymers (GFRP, also known as fibreglass). The primary beneficiaries are (i) professional civil and structural engineering designers of GFRP structures; (ii) pultruders and composites fabricators due to continually expanding use of GFRPs in construction; and (iii) the general public through the provision of sustainable structures.
In particular, Lancaster's research on pultruded GFRP materials and structures has contributed to the EUROCOMP Design Code and Handbook (1996), the world's first limit state design code for GFRP structures. This code has influenced GFRP structural design globally ever since, both pre and post-2008. Additionally, post-2008, EUROCOMP has triggered and influenced development of new European and Japanese design codes, in turn impacting designers, fabricators and the public in those geographical regions. Lancaster's research has influenced the US Load and Resistance Factor (LRFD) Prestandard (2010) and ASCE's Manual No.102 on bolted and bonded joints (2011) two codes and guidelines that will accelerate the US's application of composites in construction.
Thus, the use of Lancaster's research in these codes and guidelines has supported the construction of fibreglass-based civil structures across the globe as well as the delivery of individuals with the analysis and design skills needed by the composites industry.
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.
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.
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.
XeraCarb Ltd is a spin-out company formed in 2011 to exploit a class of ceramic composite materials co-invented by Jones. These materials were first devised in 2008 via a Materials and Engineering Research Institute (MERI) Knowledge Transfer activity and developed from 2009 onwards through a series of UK Ministry of Defence (UK MoD)-funded research projects. XeraCarb was spun out after the underpinning research won a national award in 2011 as the most promising UK materials system for commercialisation. The applications for XeraCarb's materials range from body- and vehicle-armour to kiln furniture and wear-resistant components. The company has attracted significant venture capital investment and is valued at over £1m. It has set up an independent production facility, has appointed employees, has been awarded a TSB grant, has materials undergoing trials in respect of a number of applications, and has delivered its first orders.
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).