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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.
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.
Heriot-Watt University (HWU) led the development of a supportive infrastructure for the sustainable advancement of Technical Textiles (the fastest growing textiles sector in an industry worth $25bn globally and £3bn per year to the UK economy). 452 companies have had their products or processes created or improved. (e.g. patents awarded, new companies established and research and development sustained). The research transformed how Technical Textiles were understood as marketable products in their own right; from purely functional entities to materials that operate at the interface of design and technology. This enabled the development of new technologies that enhance wellbeing and quality of life, e.g. in the health and defence sectors.
Viewing carbon nanotubes (CNTs) as very rigid polymer molecules led to research on turning them into useful materials. Strategic investments to develop different aspects of this research have been made by two separate companies. A process for the synthesis of CNTs was transferred to Thomas Swan Ltd who have made significant investment, and are now Europe's leading supplier of high-quality CNTs. In 2003 a process was invented to spin CNT fibres directly from a synthesis reactor. The process is intrinsically cheaper than the conventional process for carbon fibre and it produces a tougher and more versatile product. The University of Cambridge (UCAM) spin-out company Q-Flo Ltd (created in 2004 to achieve focus on transfer of this technology) and Plasan (multinational manufacturer of vehicle defensive armour) formed a joint venture in 2010 which has enabled the first-stage scale-up of manufacture.
CGI International Ltd is an independent producer of fire resistant (FR) glass for the building industry. A Knowledge Transfer Partnership (KTP) with the University of Leeds resulted in the launch of three new high impact performance certified glass products, exhibiting improved fire resistance, twice that of previous products. CGI's business performance improved substantially, with the new products generating in excess of £5m of new business, within the eligible REF period, in a shrinking market thereby increasing market share. Product development time was reduced by 50% and fire test costs by £20k pa. A new research and development function was created employing 4 staff and this, together with an investment in equipment, has moved CGI from being a commodity manufacturer to a technically led solution provider.
The Advanced Concrete and Masonry Centre (ACMC) at UWS was among the pioneers in development of practical self-compacting concrete (SCC) in Europe. As a lead partner, the group contributed to two large EU projects on SCC, which underpinned the European standards on SCC test methods.
The group's research has contributed to the steadily increasing use of SCC in general construction, which has brought many benefits, such as enhanced durability, improved productivity, reduced overall cost, improved working environment and sustainability. Given the massive quantities of concrete being used (>14 billion tonnes/year globally), the increased use of SCC has had important economic, societal and environmental impacts.
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.
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 world's longest high capacity terrestrial commercial communications system, now deployed worldwide, was developed from Aston University's pioneering research on the concept of dispersion managed solitons. The concepts and expertise from this research were used to develop and implement the associated system design for high capacity (1Tb/s) WDM (wavelength division multiplexing) transmission over 1000s of kilometres. Commercial development was led by Prof Doran and the core team from Aston who left the University to found Marconi-Solstis, a part of Marconi plc. Prof Doran and other key members of this team have since returned to Aston The system, now owned by Ericsson, (but still called Marconi MHL3000) has current annual sales of order $100M, and employs hundreds of people worldwide.
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.