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Polymer innovation presentation
- 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
- 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
- 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
