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Polymer innovation presentation
1.
Making Stuff (Polymer
Innovation) Ben Wood Technology Transfer Specialist © 2013
2.
Introductions… Polymer
Innovation Team Ben Wood - Technology Transfer Specialist • Background in technology demonstration of green motorsport projects • EngD in advanced composite materials • Expertise in additive manufacture and composites Kylash Makenji - Knowledge Transfer Specialist • Extensive experience in injection moulding industry • MSc and EngD in polymer processing and decoration • Expert in polymer processing and manufacturing © 2013
3.
Introductions… Polymer
Innovation Team Martin Worrall – Technology Transfer Technician • Trained CNC Programme Setter at Alvis Vehicles • Extensive experience of technology demonstration Greg Gibbons – Head of Additive Manufacturing Research • PhD in Physics from University of Warwick • World leading expert in additive manufacturing Vannessa Goodship – Principle Research Fellow • Extensive experience in plastics industry • Author of more than a dozen plastics books • Expert in polymer recycling © 2013
4.
Polymer Innovation
We make stuff… © 2013
5.
Polymer Innovation
• Working with new materials • Developing new processes • State of the art equipment “We can work with you to develop new products using innovative polymer technologies” © 2013
6.
Polymer Innovation Lifecycle
Sales and profit Growth Maturity Decline © 2013
7.
Polymer Innovation Lifecycle
Prototyping Formulating Low Volume New Materials Manufacturing Recycling Adding Functionality © 2013
8.
Polymer Innovation Facilities
130m2 Technology Hall – Prototyping/3D printing – Compounding new materials – Injection moulding – Printed electronics – Polymer chemistry © 2013
9.
Polymer Innovation Demonstrators
Low Volume Manufacturing • Prototyping • Getting to production Adding Functionality • Plastic electronics • Smart materials Recycling • Identifying properties of waste • Finding new applications © 2013
10.
Low Volume -
Concept Level 2 • Review suitable 3D printing technology • Assess need for technology • Prototypes to market products and increase sales Level 3 • New methods of • Use of equipment and expertise manufacture • Tooling for low volume production • Unique components Level 4 impossible to make any other way • New manufacturing methods • Unique products © 2013
11.
Low Volume Concept
• Additive Manufacturing (3D Printing) – More accessible, fashionable • Systems from £500 – New applications • Electronics • Fashion © 2013
12.
Low Volume –
R&D • Plasma Transferred Arc/CNC – Make metal polymer tooling in one additive process • 3D Photocopying – Charged particles © 2013
13.
Low Volume -
Project Challenge ‘Our prototypes are very valuable, but we need to show our products at trade shows’ – International sales – One-off, heavy components – Challenges with transport and security © 2013
14.
Low Volume -
Project • Solution – Knowledge exchange – Use of IIPSI software and equipment – Production of high-quality display model • Lightweight • Low cost • Kit form © 2013
15.
Low Volume -
Project • Outcomes – Reduction in transport costs – Reduced risk of damage/theft – Increased knowledge of 3D printing systems © 2013
16.
Adding Functionality -
Concept Level 2 • Identify applications • Review technologies • Added value to existing Level 3 products • Use of equipment and expertise • New methods of • Initial prototypes manufacture • New ‘smart’ components Level 4 • New functional polymer components © 2013
17.
Adding Functionality –
R&D • Spray-on electronics – ‘Electronics in a can’ • Complex printed electronics – Batteries, sensors etc – PV solar panels • Shape memory polymers – Active disassembly © 2013
18.
Adding Functionality –
R&D • Hybrid Nano ALM machine – Inkjet printed electronics – Thick, viscous materials • Ceramics, polymers, metals • Manufacture of components and electronics in one process © 2013
19.
Adding Functionality -
Project Challenge: ‘Our customer wants our product to light up’ – LEDs only work with ‘natural’ polymer – Customer wants range of colours – Surface needs to light up © 2013
20.
Adding Functionality -
Project • Solution – Knowledge exchange – Use of IIPSI expertise – Spray-on electronic lighting – Suitable for low-mid volume production © 2013
21.
Adding Functionality -
Project • Outcomes – Knowledge of new manufacturing process embedded within JSC’s technical staff – Applicable to other products moving forward – Potential new markets © 2013
22.
Polymer Recycling -
Concept Level 2 • Review processes • Segregation • Reduce material waste Level 3 • Reduce landfill costs • Test material properties • Improve carbon footprint • Identify potential applications • Add value to recycled material Level 4 • Reintegrate into raw material stream © 2013
23.
Polymer Recycling -
Research • Recycling of ‘smart’ materials – Composites – Solar panels – Plastic electronics © 2013
24.
Polymer Recycling -
Projects Challenge: ‘What can we do with 3t/day of waste plastic?’ – Food contamination – Mixed colours – Low value © 2013
25.
Polymer Recycling -
Projects • Solution: – Manufacture of test samples – Analysis of properties – Knowledge exchange – Applications identified © 2013
26.
Polymer Recycling -
Projects • Outcome: – Added value – Landfill costs reduced – Environmental footprint improved © 2013
27.
Funded Research Projects
• Simpact Engineering Ltd – Simulation and FEA consultancy • Shorter KTP – simulation of sustainable materials – 60% funded by TSB – 6 month project – Full-time Project Associate – 10% of a Senior Research Fellow © 2013
28.
Funded Research Projects
• Project Outcomes – New job created – Highest ever annual turnover – Unique capability in sustainable materials – New customers/markets • Follow-on – IIPSI Internship, 8 weeks © 2013
29.
How IIPSI Can
Help… • Knowledge Exchange – Expertise focussed on your business • Access to Equipment and Facilities – ‘Try before you buy’ – Understand benefits and pitfalls • Individual Projects – R&D Level collaborations © 2013
30.
Down to the
technology hall… • IIPSI Technology Hall taster session – Rapid tooling – 3D printing applications – (Not just manufacturing!) • Preview of IIPSI equipment – Available for use by West Midlands SMEs © 2013
31.
“We can work
with you to develop new products using innovative polymer technologies” We’d love to hear your project ideas… BEN WOOD @BENJAMINMWOOD B.M.WOOD@WARWICK.AC.UK © 2013
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