polymer innovation presentation

© 2013

Making Stuff (Polymer Innovation)

Ben Wood

Technology Transfer Specialist

© 2013

Ben Wood - Technology Transfer Specialist • Background in technology demonstration of green motorsport

projects • EngD in advanced composite materials • Expertise in additive manufacture and composites

Introductions… Polymer Innovation Team

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

Greg Gibbons – Head of Additive Manufacturing Research • PhD in Physics from University of Warwick • World leading expert in additive manufacturing

Introductions… Polymer Innovation Team

Vannessa Goodship – Principle Research Fellow • Extensive experience in plastics industry • Author of more than a dozen plastics books • Expert in polymer recycling

Martin Worrall – Technology Transfer Technician • Trained CNC Programme Setter at Alvis Vehicles • Extensive experience of technology demonstration

© 2013

Polymer Innovation

We make stuff…

© 2013

“We can work with you to develop new products using innovative polymer technologies”

Polymer Innovation

• Working with new materials

• Developing new processes

• State of the art equipment

© 2013

Polymer Innovation Lifecycle

Growth Maturity Decline

S

ale

s an

d p

rofi

t

© 2013

Polymer Innovation Lifecycle

Prototyping

Low Volume Manufacturing

Adding Functionality

Recycling

Formulating New Materials

© 2013

Polymer Innovation Facilities

130m2 Technology Hall

– Prototyping/3D printing

– Compounding new materials

– Injection moulding

– Printed electronics

– Polymer chemistry

© 2013

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

Low Volume - Concept

• Review suitable 3D printing technology

• Assess need for technology

Level 2

• Use of equipment and expertise

• Tooling for low volume production

Level 3

• New manufacturing methods

• Unique products

Level 4

• Prototypes to market products and increase sales

• New methods of manufacture

• Unique components impossible to make any other way

© 2013

Low Volume Concept

• Additive Manufacturing (3D Printing)

– More accessible, fashionable

• Systems from £500

– New applications

• Electronics

• Fashion

© 2013

Low Volume – R&D

• Plasma Transferred Arc/CNC

– Make metal polymer tooling in one additive process

• 3D Photocopying

– Charged particles

© 2013

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

Low Volume - Project

• Solution – Knowledge exchange

– Use of IIPSI software and equipment

– Production of high-quality display model • Lightweight

• Low cost

• Kit form

© 2013

Low Volume - Project

• Outcomes

– Reduction in transport costs

– Reduced risk of damage/theft

– Increased knowledge of 3D printing systems

© 2013

Adding Functionality - Concept

• Identify applications

• Review technologies

Level 2

• Use of equipment and expertise

• Initial prototypes

Level 3

• New functional polymer components

Level 4

• Added value to existing products

• New methods of manufacture

• New ‘smart’ components

© 2013

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

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

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

Adding Functionality - Project

• Solution

– Knowledge exchange

– Use of IIPSI expertise

– Spray-on electronic lighting

– Suitable for low-mid volume production

© 2013

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

Polymer Recycling - Concept

• Review processes

• Segregation

Level 2

• Test material properties

• Identify potential applications

Level 3

• Reintegrate into raw material stream

Level 4

• Reduce material waste • Reduce landfill costs • Improve carbon footprint • Add value to recycled

material

© 2013

Polymer Recycling - Research

• Recycling of ‘smart’ materials

– Composites

– Solar panels

– Plastic electronics

© 2013

Polymer Recycling - Projects

Challenge:

‘What can we do with 3t/day of waste plastic?’

– Food contamination

– Mixed colours

– Low value

© 2013

Polymer Recycling - Projects

• Solution:

– Manufacture of test samples

– Analysis of properties

– Knowledge exchange

– Applications identified

© 2013

Polymer Recycling - Projects

• Outcome:

– Added value

– Landfill costs reduced

– Environmental footprint improved

© 2013

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

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

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

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

BEN WOOD @BENJAMINMWOOD B.M.WOOD@WARWICK.AC.UK

We’d love to hear your project ideas…

“We can work with you to develop new products using innovative polymer technologies”