Industrial Collaborations

Affresol Ltd manufactures a range of products using a new type of composite material called Thermo Poly Rock (TPR). TPR is more sustainable than concrete and Affresol have already successfully launched several products utilising the material. TPR uses waste plastics diverted from landfill as a raw material and the production is currently based on empirical knowledge of how the production should be set up in order to ensure that the product complies to the designed standards.

The project will capture the existing knowledge, introduce a state of the art system to monitor and control key production processes and manage the collected data to produce meaningful information that can be used to increase automation and autonomy of the utilised systems. The outcome of the project will boost the production of TPR, provide the market with a sustainable alternative to concrete and reduce the amounts of waste plastic ending in UK landfills.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Status: Completed

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Agroceutical Products is a Welsh company specialising in the production of galanthamine from from sustainable resources. Galanthamine has been approved by several countries for the symptomatic treatment of senile dementia of the Alzheimer's type. Synthetic Galanthamine is costly and difficult to synthesize however Agroceutical Products’ production method is cost effective, scalable and reliable.

Agroceutical Products source of galanthamine is daffodils grown above 1000 feet in the Welsh hills. They developed a method to extract galanthamine from daffodil juices which also contain other compounds of medicinal values. In the current project this extraction process will be improved to increase the production yield.

The outcome of the project will identify process parameters impacting the manufacturing process to provide solutions to improve the extraction efficiency. The technology developed and the results obtained at the lab scale will allow the collaboration to move towards scale-up of the process.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Powys

Status: Completed

Millions of holes are drilled (single or multi stage operations) into aircraft structures and the positioning of the drill is provided by drilling templates. These templates, manufactured mainly from wrought 7075 Aluminium machined plates, have proven effective over time. However, a large number of these templates are over 10 kg leading to ergonomic issues, as they have to be positioned in place manually by operators. To solve this problem, Airbus is considering alternative lightweight materials with improved performance. In addition, there are opportunities to use alternative materials in other tooling jigs - namely the leading edge flags used to hold different wing structures in place during assembly and riveting operations - and reduce their weight through topology optimisation. The objective is to reduce the overall weight of the concentric collet drilling templates and leading edge flags by using alternative lightweight materials and topology optimisation techniques. The outcome of the research will provide Airbus with a costeffective and innovative drilling template solution to be used for creating holes and riveting applications into a variety of materials used in aeronautical structures. In addition, the research will provide Airbus with topologically optimised leading edge flags that are lighter in weight and easier to handle by operators.

Expertise: Advanced Materials Technology

Academic Partner: Cardiff University

Location: Flintshire

Status: Completed

Airflo is a leading designer and manufacturer of high performance fly fishing line products. Established in 1983 the company has a long history of innovating in the fly-fishing line industry. Distributed globally to 32 countries Airflo are currently the only company using PU vs PVC. The innovative nature of the company continues with innovative process improvements and new innovative processes aimed at driving increased growth and profitability. The latest example of
this is in the use of sea harvested plastic to manufacture its carrier spool.

Recently, Airflo has developed an advanced range of fly-lines with ridged coatings that reduce surface friction and improve shoot-ability, each breakthrough offering a truly tangible improvement to the end user. Airflo operates a complex coextrusion process for coating thermoplastic polyurethane onto their lines using a crosshead die allowing for to vary the coating materials and coating thickness in a continuous process. In this R&D project the company will collaborate with ASTUTE to gain improved understanding of how to optimise dies for their process, to reduce development time and costs on new products, increase productivity, and reduce scrap and carbon footprint. ASTUTE will apply expertise in flow properties of complex materials and advanced computer modelling to gain detailed insights into the process, supported by experimental work and production trials at the company. Anticipated outcomes will help Airflo capitalise on a growing market as well as break into new ones. Improved efficiencies will also allow the company to spend more time on R&D, developing the next generation of product to help further grow the business. More widely, the work will provide deep insights into the commercially important wire coating process by the use of advanced computational methods not previously applied in this field.

Location: Powys

Academic Partner: Swansea University 

Expertise Area: Computational Engineering Modelling and Advanced Materials Technology

The Aluminium Lighting Company (ALC), based in Cymmer near Port Talbot, manufactures a range of aluminium lighting columns, and was the first business to introduce the benefits of extruded aluminium lighting columns into the UK.

Effective lighting illuminates hazards involving road traffic, ranging from vehicles travelling at high speed to cyclists and pedestrians. Lighting columns are designed by the manufacturer for a specific use according to British Standard EN 40-3-2&3. Once installed, the performance of the column is likely to deteriorate over time. This can be due to factors such as: progressive corrosion; deteriorating foundation conditions; and collision impact.

There are a variety of options to assess the structural condition and performance of a column. They range from superficial visual inspections to physical or ultrasonic tests. They are intermittent, and only give data at the time of the inspection or test. Some tests can be relatively expensive and disruptive, requiring road closure or management.

The respective phases of this project aim to identify more closely how a column is actually performing in real time against a predicted level of performance. This will help identify if a column is deteriorating structurally and better predict when a column may fail and need to be replaced.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Neath/Port Talbot

Status: Completed

The Aluminium Lighting Company (ALC), based in Cymmer near Port Talbot, manufactures a range of aluminium lighting columns and was the first business to introduce the benefits of extruded aluminium lighting columns into the UK. They would like to investigate “vortex shedding” which is a complex fluid flow phenomenon that can induce vibrations in structures exposed to the wind.

The proposed project will use Swansea University’s established scientific expertise in Computational Fluid Dynamics (CFD) and Fluid-Structure Interaction (FSI) to investigate how vortex shedding occurs around lighting columns. It is anticipated that this will allow ALC to introduce new types of cost-effective lighting columns with increased resistance to wind-induced damage.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Neath/Port Talbot

Status: Completed

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Amnitec is a global leader in the design, development, manufacture and support of performance critical flexible engineered solutions for the transfer of gases and fluids in extreme environments. A partner to the aerospace and defence industries for over seven decades. Applications include the safe and reliable performance in refrigeration, medical, power generation, food and beverage, general industrial, and the oil and gas industries.

This collaborative research opportunity with the ASTUTE 2020 team would allow for a greater understanding of the metallurgy of a copper to stainless steel welded joint. The research aims at enhancing the quality of these welds to eliminate leakage of gases or fluids through thorough investigations of the welded zone, any related flaws observed in the company’s welding process and subsequent revision of the welding process. The aim being to reduce scrap in products that employ this welding method and improve quality & competitiveness in a narrow market.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Merthyr Tydfil

Status: Completed

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Avantis and Sodaflexx sister companies closely working together on the design, marketing, installation inspection, installation, commissioning and after care of Ships Exhaust Gas Dry Scrubber Systems.

The fundamental governing principle of the system is the efficient and timely mixing of Sodium Bicarbonate with the main engine exhaust stream within the main engine uptake ducting.

As the chemical reaction time is finite and the exhaust gas velocity and length of exhaust pipe are set it is critical that efficient mixing is achieved from the moment of injection. Furthermore, design, number, orientation and position of the sodium bicarbonate injectors is critical to efficient mixing.

As both Avantis Marine and Sodaflexx are embarking on the first commercial installation of such a system and yet do not have any practical or empirical information regarding the positioning or numbers of injection points. It is therefore, of the utmost importance that we have some timely, meaningful support for the position we fit the injector or injectors.
We would like ASTUTE to model the exhaust pipe from the Main Engine turbo charger to the inlet to the composite boiler and run various gas flow and injection computer simulations to determine the most optimum injector(s) position.

This information will be used by Avantis Marine to determine the points mentioned above and ultimately the cost and time for installation. This information will be used by Sodaflexx to determine the points mentioned above, the whole system cost to the Owner including the installation and ultimately the commercial success of the project.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: The Vale of Glamorgan

Status: Completed

BCB International are Cardiff‐based manufacturer of life‐saving specialist equipment. Over their 160 year history, BCB International has built up unique knowledge and expertise in developing life‐saving and protective equipment for those operating in challenging environments. They have been awarded two Queen’s Awards for export achievement.

Their clients include:

• United Nations
• The Red Cross
• BAE Systems
• Ministry of Defence

There is a growing demand for their products and they have moved into new facilities in Cardiff. BCB have successfully positioned their product range to capitalise in this market for several years. The current work will play a critical role in the company meeting its future growth targets, through enhancing the resilience of their manufacturing systems and supply chains.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Cardiff

Status: Ongoing

Reducing the noise and improving the sound quality of vehicles’ interior space is one of the challenges to enhance passengers’ experience. Heating, Ventilation and Air Conditioning (HVAC) unit is a major noise source in a vehicle’s interior space. Bergstrom Ltd manufactures HVAC units and want to ensure their units fall below the noise threshold specified by their customers. The company is currently testing the noise at maximum operating speed. Although this suits their needs to ensure they meet the threshold, it in nowhere near rigorous enough to identify problematic noise early in development. This sometimes led to modifications being required late in the development process to remove noise which, although below the required threshold, is irritating.

This project aims at helping the company to identify, analyse, and evaluate the noise that is produced by the HVAC units that are manufactured by the company. This include detailed modelling of the HVAC unit and intensive simulation and then experimentally evaluate the unit and precisely identify the main causes for the noise.

Expertise: Computational Engineering Modelling & Manufacturing Systems Engineering 

Academic Partner: Cardiff University

Location: Caerphilly

Status: Completed

Biotage GB Limited manufacture flash chromatography columns, involving the packing of silica powder into plastic containers of various size. To produce good chromatography the columns must be packed evenly and tightly, with no voids. the quality of columns is checked in batches using destructive processes which results in material and financial waste.

The aim of this project is therefore to establish an innovative method for verifying column quality. The project will consider the acoustic signatures of various manufactured flash chromatography columns to establish a method for verifying individual column quality. This will reduce process waste and cost, increase product value, and advance the value of the manufacturing process and ecosystem.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Caerphilly

Status: Ongoing

British Rototherm design and manufacture a range of precision components for the oil, gas and other processing industries. The company has been present in Port Talbot since 1969 and grown into a global provider of engineering products and services.

The market is driving the design teams to take into consideration, not only the product performance but also the impact it has on the working environment. For this reason, British Rototherm wish to develop a market leading capability in noise prediction for orifice pressure reducers with the assistance from ASTUTE 2020. This will be carried out via a collaborative R&D project, in which ASTUTE 2020 will focus on the development of the computational modelling technique and the company’s expertise in flow control and measurement is to underpin the experimental validation program.

The sought technical output from the project is a demonstration of capability for numerical modelling tools to predict noise levels from pressure reducers, which will help cement Rototherm’s leadership in this niche field.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Neath/Port Talbot

Status: Completed

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Brother Industries Limited is a Japanese multinational manufacturer of diverse consumer products, including printers, scanners, fax, label printers industrial sewing machines, and other computer based technology products.

Brother Industries (U.K.) Ltd. (BIUK) is based in North Wales, and employs around 160 people. Their USP is to act as the Recycling Technology Centre (“RTC”) for the global Brother Group, to develop the technology for recycling printer consumables. Their vision is to adopt the principles of the “Circular Economy” as an ethical and sustainable and profitable business model.

The proposed collaborative research is aimed at developing the knowledge, processes, and technology, using both open loop and closed loop recycled plastic materials. The know‐how will then be adopted into the manufacturing environment to mould a variety of components for consumer products.

The expected outcome will be to reduce the amount of resources used in production by applying a scientific approach to mix manufacturers of compatible recycled grades of materials and influence Brother Japan’s design cycle to allow the inclusion of recycled materials. One of the Impacts could be the increase in employment within the local community.

Expertise: Advanced Materials Technology, Circular Economy

Academic Partner: Swansea University

Location: Wrexham

Status: Ongoing

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Calon Cardio‐Technology Ltd. (Calon) has been developing Ventricular Assist Devices (VADs) in close collaboration with Swansea University since 2007. The company has been successful in attracting investment to ensure its growth in a very competitive market. The company has conducted lab and small scale in vivo experiments and aims to start clinical trials in 2018.

The current project will consist of five work packages, four will heavily utilise the available high-performance computing platforms: the newly commissioned Engineering cluster and ASTUTE 2020 high-performance workstations. The fifth work package will utilise the Additive Layer Manufacturing (ALM) capability at the College of Engineering.

Three of the four computational work packages will investigate the pump performance in real life conditions (flow under heart pulsatile pressure, modelling blood as a multiphase fluid, flow patterns in a 3D model of real‐life failed left ventricle). The fourth is aimed at improving the current blood damage prediction capabilities. Experimental data needed for benchmarking the blood damage model will come from Calon’s labs.

The outcome of the current project will expand knowledge of the relationship between blood flow in complex geometries and VAD’s hydraulic and haemolytic performance, and utilising the expanded knowledge in product development to shorten time to market. Additionally, the feasibility of additive layer manufacturing (ALM) in VADs manufacturing will be assessed.

The impact of the project will be assessed by:

• Continued attraction of funds to the company by remaining competitive through advanced technology development.
• Increased exposure of the company through publications and presence at international conferences.
• Raised profile of Swansea University through research publication.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Swansea

Status: Completed

Calon Cardio Technology have been developing heart pump technologies in close collaboration with Swansea University since 2007 and focus on their ventricular assist device, the miniVAD. The company's success has attracted investment to ensure the growth of the company. The company has conducted lab and in-vivo experiments and aims to obtain the first human data in 2017¹

The project consists of phased work with gateway approvals. With a target of obtaining human data in 2017, the company needs to come to a manufacturing solution without compromising performance. The role of computational modelling is to highlight potential problems and avoid a costly iterative experimental process.

The project focuses on the development of more accurate modelling methods for blood damage based on an improved damage model characterisation method and a more accurate reproduction of experimental conditions.

The development of a suitable technique to assess the effect of the pump on pulsatility is included as a work phase. Finally, the project will also investigate the distribution of transported blood components in the flow, focussing first on heterogeneous haematocrit modelling and then on the factors affecting clotting. The work will be undertaken using experimental data from published literature for benchmarking and experimental data obtained using the company's own pump design.

The outcomes are increased knowledge of blood flow modelling methods, flow behaviour and thus an applied result for the company in the form of assessed performance of blood pumps in general and VADs in particular.

The impact is assessed to be: Continued attraction of funds to the company by remaining competitive though advanced technology development. Increased exposure of the company through publications and presence at trade/academic conference.

Raised profile of the HEI through research publication. [1] http://www.insidermedia.com/insider/wales/140902-/

Expertise: Computational Engineering Modelling 

Academic Partner: Swansea University

Location: Swansea

Status: Completed

Calon Cardio‐Technology Ltd. (Calon Cardio) has been developing Ventricular Assist Devices (VADs) in close collaboration with Swansea University since 2009. The company has been successful in attracting investment to ensure its growth in a very competitive market. The company aims to start clinical trials in 2020.

The current project will consist of three work packages. The first work package is related to the development of a miniaturised VAD and will focus on investigating the feasibility of VAD miniaturisation and evaluate its hydraulic and haemolytic performance. The second is aimed at improving the current blood damage prediction capabilities utilising new experimental data from Calon Cardio’s laboratory. The final work package will evaluate the effect of outflow graft distortion on the VAD’s hydraulic and haemolytic performance.

The outcome of the current project will expand knowledge related to:

• Commercial in Confidence V11_220818 1
• Blood flow in miniaturised VADs.
• VAD’s performance with outflow graft distortion.
• Blood damage prediction.

The impact of the project will be assessed by:

• Continued attraction of funds to the company to enable it to start clinical trials.
• Using advanced modelling techniques to accelerate new product development.
• Increased exposure of the company through publications and presence at international
  conferences.
• Raised profile of Swansea University through research publication.
  
  Expertise: Computational Engineering Modelling 

Academic Partner: Swansea University

Location: Swansea

Status: Ongoing

The current project will provide outputs that will be useful to Calon’s FDA approval application for their pump, the MiniVAD™. The project will build on and expand the knowledge acquired from previous projects. It will investigate the interplay of the MiniVAD™ and the vascular system and predict the performance of the MiniVAD™ under normal and abnormal physiological conditions. Additionally, it will investigate the feasibility of employing machine learning methods to predict and optimise the performance of VADs as a function of the complex blood pathway parameters and operating conditions

Expertise: Computational Engineering Modelling and Manufacturing Systems Engineering

Academic Partner: Swansea University

Location: Swansea

Status: Ongoing

Camplas Technology Ltd., based in Bridgend, specialises in manufacturing glass reinforced plastic (GRP) tanks of various scales.

Camplas Technology Ltd. has teamed up locally with Marine Power Systems Ltd. to manufacture a custom GRP tank to be used as a floater in a novel marine power system to be used to harvest wave energy. The proposed floater has to sustain high level of external pressure when immersed in sea water and take the loads imposed by the dynamic anchoring system.

Camplas Technology Ltd. has manufactured several thousand tanks by the helical filament winding process; however, the proposed floater is beyond the scope of the current design and manufacturing standards and will require an in-depth analysis from first principles.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Bridgend

Status: Completed

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Camplas Technology Ltd, based in Bridgend, specialises in manufacturing glass reinforced plastic (GRP) tanks of various sizes that are used either above or underground. Depending on the specific application, tanks are subjected to various types of loadings such as liquid inner pressure, outer ground pressure, vacuum, ageing, fatigue and wind loads. The company has invested heavily in R&D, and in 1985 built its first computer controlled helical filament winding machine. Since then, the company has manufactured several thousand tanks that conform to BS4994 –1987. The company is dedicated to the improvement of the environment through the development of the best available technology at affordable cost, particularly in the fields of pollution prevention, improvement in water quality and storm control.

Camplas is now seeking help from ASTUTE 2020 to develop a user friendly custom‐made computer‐based expert system to provide manufacturing guidance that fulfils the new requirements of the BS EN13121‐3:2016 standard. Advanced computational modelling, support by experimental trials on decommissioned GRP tanks will be used to validate and guide the development of the computer system.

Expertise: Computational Engineering Modelling, Advanced Materials Technology & Manufacturing Systems Engineering

Academic Partner: Swansea University

Location: Bridgend

Status: Completed

Camplas Technology Ltd, based in Bridgend, has 50 years’ experience in designing and building large composite structures utilising the Helical Filament Winding Process. More recently, these structures having been introduced for the marine sector; including both manned and unmanned mini‐submarines, sub‐sea pipelines and a number of prototypes for tidal power generators.

Camplas Technology Ltd is currently seeking to manufacture a novel marine power system for the harvesting of wave energy. The project seeks to demonstrate the concept of utilising water flow acceleration through an orifice, by placing a specifically shaped duct around a turbine in order to effectively channel and accelerate the flow through the turbine; thereby, hypothetically increasing power output.

The Astute2020 team has been tasked with investigating the underlying physics of the process and through the application of computational fluid dynamics, assessing the viability of the concept, i.e. will utilising a duct sheathed turbine improve performance.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Bridgend

Status: Completed

Camplas Technology Ltd. specialise in the manufacture of glass‐reinforced plastic (GRP) chemical storage tanks of various shapes and sizes for use above or underground. Depending on the specific application, tanks are subjected to various types of loadings such as liquid inner pressure, outer ground pressure, vacuum, ageing, fatigue and wind loads. The company has invested heavily in R&D, and in 1985 built its first computer controlled helical filament winding machine. Since then, the company has manufactured several thousand tanks conforming to BS4994 – 1987, and more recently BS EN13121‐3:2016.

The objective of this project is a feasibility study for the development of Floating Offshore Wind Turbine (FOWT) support structures in reinforced composites using the company’s award-winning expertise and experience gained over 54 years of innovation in this field. The manufacture of these structures will form part of a development to build an advanced composite winding facility to satisfy the known and urgently needed demand for floating wind turbine structures to assist in achieving the government's objective to reach zero emissions

Location: Bridgend 

Academic Partner: Swansea University 

Expertise Area: Computational Engineering Modelling and Advanced Materials Technology

Carlisle Brake & Friction (CBF) is a leading solutions provider of high performance and severe duty brake, clutch and transmission applications to OEM and aftermarket customers in the mining, construction, military, agricultural, motorsports, industrial and aerospace markets.

Carlisle currently relies on human operators to undertake inspections after their twin booster parts have been washed, as well as the assembling of the twin boosters before testing. The Carlisle Twin Boosted Master Cylinders utilise patented Hydraulic Boost Assist technology to reduce pedal efforts by up to 90% when compared to traditional Master Cylinders. This enables vehicle manufacturers to provide premium braking performance for their customers with automotive pedal feeling for reduced driver fatigue and improved driver comfort.

The research will assess the feasibility of introducing automation to Carlisle’s current production line. This could help to reduce the pressure on workers by taking over repeatable work. Introducing robots to the production line, the inspection outputs from a robot are easily accessible, providing the company with quantitative data, analysis of which will lead to continual improvement. The repeatability of a robot will also help to reduce variability on key assembly tasks.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Torfaen

Status: Completed

Cellesce has invented and patented a unique bioprocess for the expansion of Patient‐Derived Organoids (PDOs). PDOs are a biologically relevant, patient‐representative model that is revolutionising drug discovery and supporting therapeutic decisions for tailored patient treatments.
A next‐generation bioprocess to scale PDO production to 5 times the current capability is currently in development, for use as an in vitro platform for high‐throughput compound screening, early in the drug‐development pipeline.
The project will use data outputs from Cellesce’s pilot bioreactor runs and manufacturing digitalisation technologies to develop a digital twin model. This will inform predictions of cell numbers and optimise growth conditions.
During manufacturing runs, the digital twin will monitor data discrepancies and automatically modify process parameters or alert the operator to intervene. The project will increase autonomy and reliability of bioreactor control, assisting in standardising inter and intra batch reproducibility.

Digital monitoring will make a significant contribution to Cellesce’s expansion plans as this is critical for the consistent and reproducible production of PDOs for high‐throughput drug discovery. Scaling PDO production further, will enhance Cellesce’s current position in the drug discovery market by offering PDOs in greater quantities at comparatively lower cost.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Status: Ongoing

Based at two sites in Cardiff, Celsa Manufacturing UK Ltd. is the largest producer of steel reinforcing bar in the UK and one of the largest manufacturers of other steel long products (including wire rod, flat bars, channels and angles). All steel manufacture is based initially on recycling ferrous scrap metal using the electric arc furnace (EAF) route. The ASTUTE EAST project will study the operation and performance of the EAF at Cardiff and the technical work will include consideration of Static VAR (Reactive Power in Volt-Ampere) Compensation (SVC) equipment to improve the power delivery profile to the furnace.

The anticipated outcomes will be to optimize the furnace operation and hence reduce power consumption, eliminate the voltage flickers, and reduce the electrode consumption per tonne of steel produced. The impact of the project, if successful, will contribute to enhanced operation of the arc furnace as well as reduced cost of production of steel made in this method.

Expertise: Manufacturing Systems Engineering & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Cardiff

Status: Completed

Champion Manufacturing have been producing high quality equestrian helmets for many decades. These helmets are engineered to mitigate impacts, in addition to surviving additional external factors (such as crushing forces). The engineering behind these shells has remained relatively static for many years, serving to distribute force to the underlying protective liner, and provide other protective benefits.

Further enhancements to the engineering of the shell have been identified as having potential for improved performance. Cardiff University will comprehensively collaborate with Champion to explore the use of advanced technologies and sustainable engineering methods, to further improve the performance of this shell.

This work has the potential to be transferable to other PPE products within the Champion manufacturing family.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Cardiff University

Location: Cardiff

Status: Ongoing

Cintec manufacture anchoring solutions, which are implemented in masonary structures globally. These systems allow for retrofitting of heritage buildings, protecting them from environmental hazards, and thus extending their lifetime.

A new anchor that improves performance, whilst being more commercially viable, has been developed in conjunction with Cardiff University. This project aims to further develop this anchor, and test it within a representative structure. During the course of the project, the manufacturing viability of the anchor will be continuously analysed. This will ensure future commercialisation of the device will be successful.

Expertise: Computational Engineering Modelling

Academic Partner: Cardiff University

Location: Newport

Status: Ongoing

Cintec Ltd is a designer and manufacturer of the pre‐eminent anchoring solution for masonry structures operating internationally. The patented Cintec anchoring system is constructed by injecting a proprietary cementitious fluid grout around a metal tie enclosed in a fabric sock, which has already been placed in an oversized drilled hole. The engineered solution reinforces an array of materials — stone, concrete, clay, terra cotta, timber — in historical buildings, masonry bridges, monuments, railway structures, retaining walls, without visibly altering the structure’s appearance.

A new anchor recently designed for seismic loadings has proven to be too expensive to manufacture and therefore Cintec redesigned the product. This project aims at conceiving manufacturing process and validating the new device, ensuring it exceeds required performance criteria.

The project is composed of six phases and comprises engineering review, computational/ investigation and experimental testing. The collaborative project is based on the extensive experience of the company and on the technical expertise of the research team at Cardiff University. The outcome of the research will provide the company with an economically competitive and innovative anchoring solution to be employed in earthquake‐susceptible constructions worldwide.

Expertise: Manufacturing Systems Engineering & Computational Engineering Modelling 

Academic Partner: Cardiff University

Location: Torfaen

Status: Completed

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Continental Teves manufacture automotive braking systems. The business is evolving from a high volume to a lower volume manufacturer supplying significantly larger number of Automotive companies and the after‐market.
This transition to lower volume, across a wider product range requires the company to evolve, develop and deploy new technologies to flexibly adapt to this new situation. This collaborative research will assess the feasibility of introducing advanced robotics and additive layer manufacturing to reduce lead time and improve the flexibility and cost competitiveness of the production lines.
The collaborative research will assist the company in developing a digital manufacturing capability that aligns with the roadmap to secure the future of the factory.

Expertise: Manufacturing Systems Engineering & Advanced Materials Technology

Academic Partner: Cardiff University

Location: Blaenau Gwent

Status: Ongoing

Crossflow Energy Company Ltd., based in Port Talbot, are developing a range of novel Vertical Axis Wind Turbines aimed at a niche market in the mid-range (50-500kW) Wind Turbine sector. The company has previously worked with ASTUTE on research into the aerodynamic flow of air through the turbine under steady state conditions. This has helped them secure substantial investment to allow the construction of a full-size proof of concept turbine in Port Talbot.

A new project with ASTUTE 2020 has now been proposed that will extend the previous research to cover transient wind loading conditions (as associated with sudden wind gusts and changes of wind direction) so that the behaviour of the turbines under realistic conditions can be investigated.

If successful, this research will enable the company to design the optimised pre-production turbine for commercial manufacture.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Neath/Port Talbot

Status: Completed

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Crossflow are developing a portable Integrated Energy System (IES) unit. It is a solar and wind energy solution that can be deployed in a container. This project will investigate the remote monitoring and remote operation of one of Crossflow Energy's IES units, including storage, transmission and intelligent interpretation of the data, supporting the first remote deployment of an IES. It will address the human factors issue of remote presentation of high bandwidth data. A prototype solution will be deployed on Crossflow's prototype turbine, providing both valuable feedback on the operation of the prototype turbine, as well as experience of deploying remote monitoring that can be fed into a commercial solution.

Expertise: Manufacturing Systems Engineering

Academic Partner: Aberystwyth University

Location: Neath/Port Talbot

Status: Completed

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The current hair removal device manufactured by Cyden Ltd is a product targeted at the consumer market. It is distributed by Braun as well as sold directly and is one of the two leading products of its type on the market in terms of units sold. It is intended for a particular range of skin and hair types and tones. The aim of this project is to identify improvements and modifications to the existing product in order to cater for a wider range of skin and hair types and tones. This would then lead to increased market penetration and hence increased manufacturing, all of which is done in WWV. The project will develop customised 2D and 3D computer models of light‐tissue interaction (based on existing models) for a range of hair types and skin/hair tones. These will be customised for the company using experimental data on a range of light sources and sample client groups‐ supplied by the company. The expected outcomes are:

• new product for company and the market
• increased jobs
• Increased investment by the company.

Expertise: Computational Modelling Engineering

Academic Partner: University of Wales Trinity Saint David

Location: Swansea

Status: Completed

Divemex are experienced in maritime industries and recognised the need for a new type of anchor (patent has been applied for and granted), that can be accurately deployed with minimal dragging to embed it. CSM Pressings have been engaged as the manufacturing partner for the product.

Project: To evaluate the performance and model key parameters, particularly how it embeds in the sea floor, to determine opportunities for further optimisation, including manufacturing.

Outcome: To determine performance parameters and a testing methodology in conjunction with Divemex. Demonstrate performance under varying deployment and recovery conditions, with particular reference to accuracy/repeatability of launch position and embedded final position.

Impact: Anchor design is historically empirical in nature and has seen little recent evolution. Current designs often drag some distance before the required engagement with the sea floor, and laying anchors can, therefore, involve several attempts before the anchor is confidently fixed. This new type of anchor that can improve the fixing process and be accurately positioned could replace the current practice of deploying a large concrete block leading to a reduction in environmental impact.

The use of computational analysis techniques and rigorous testing will allow this anchor to be scientifically optimised, rather than being based exclusively upon current best practice.

Expertise: Manufacturing Systems Engineering & Computational Engineering Modelling

Academic Partner: Cardiff University

Location: Swansea & Rhondda Cynon Taf

Status: Completed

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Dr. Zigs Ltd. Is a Welsh company that specialises in the manufacture and production of the highest quality and most eco‐friendly, low plastic, palm‐oil free bubbles in the world. The company followed sound environmental ethics from the start and their motto is “Changing the World One Bubble at a Time!”

The bubble mix manufactured by Dr. Zigs contains a polymer and the uniform dispersal and properties of the polymer is key to the performance of the mix in consistently producing the bubbles. The current project will look at manufacturing parameters impacting the bubble mix performance and how to overcome those that will negatively impact the quality of the mix.
Defining shortcomings of the current manufacturing process will help Dr. Zigs optimise their manufacturing process and production facilities allowing them to expand into new markets around the world. The proposed project will benefit both parties in understanding and gaining know how in polymer solution mixing process’ susceptibility to the different manufacturing factors.

Expertise: Advanced Material Technology

Academic Partner: Swansea University

Location: Gwynedd

Status: Ongoing

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EFT Consult is an engineering consultancy company specialising in enhancing building performance. One aspect of their work is to provide environmental monitoring solutions for inside environments. EFT Consult are currently developing a multi‐sensor monitoring system for internal environments and they plan to use leading technical and manufacturing knowledge and methodologies to enhance their current working prototype.
The project objective is to review the existing Sensor prototype to ensure that is it is based on the leading technical and manufacturing knowledge and methodologies This project is to conduct research in the following areas to feed into the development of the new system. The objective of the project will be to provide information for the production version to help to comply with the forthcoming British Standard in Indoor Environmental Quality and to allow the product to be mass produced as easily and economically as possible. Therefore, areas for project review include research and analysis of the (i) Casing / enclosure in terms of the best material for the enclosure to allow low cost scalable production, and the most viable method of manufacture, recyclability, mass production and aesthetics; (ii) Components – sensors, sensor array configuration, (iii) Communication to inform the best communication technology to be used whilst ensuring information security and minimising power use; (iv) Power to determine the best method to power the device with minimal constraints.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Status: Ongoing

15 million tonnes of food waste are being produced every year in the UK and the waste is typically disposed of in bins and then collected at a cost to the waste producer. Food digester manufacturer EcoSphere, is targeting in reducing the volume of this waste, reducing the cost of disposal and is working towards creating value from this waste that will benefit the “owner” of it. ASTUTE 2020 will assist the company in engineering a state of the art digester that will treat food waste more efficiently, reduce waste’s volume up to 90% and create a competitive advantage for a product that will be manufactured within West Wales and Valleys. The project will conduct research on food waste treatment technologies, model the digester operation, develop a smart control system for the digester and finally, suggest improvements and enhancements to be included by the company.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University & Aberystwyth University

Location: Bridgend

Status: Completed

Abstract:

At their Ebbw Vale factory, Energizer Auto Ltd manufacture a wide range of automotive care products. This collaborative research project will analyse the decision‐making involved in the blending process using the statistical Analytical Hierarchy Process (AHP) and will investigate alternative ways to improve the quality control of the blending process using digital‐assisted technologies that could improve the decision‐making identified in the AHP analysis. Supply chain fluctuations have increased the burden on blending operators. Informed by the AHP analysis, the improved process will provide real‐time guidance to the blending operator to reduce the possibility of operator error.

Expertise: Computational Modelling & Manufacturing Systems Engineering

Academic Partner: University of Wales Trinity St David

Location: Blaenau Gwent

Envirowales Limited recycle scrap lead acid batteries at their manufacturing base in Ebbw Vale. The plant opened in 2006 and is one of the most modern lead recycling facilities in Europe, employing around 140 people in the local economy.

Currently, the lead is recovered and purified before being sold into a range of standard markets that include the construction industry and further battery manufacture. Recently the company has identified higher value-added applications for lead that include specialist anodes used in the global mining industry for recovery of metals such as copper and zinc from their ores.

To target this market they need to undertake extensive research into the specialised lead alloys that are required for this application. Envirowales would thus like to collaborate with ASTUTE 2020 to utilise Swansea University’s expertise in electrochemistry and advanced materials. In the first instance, this will involve a review of existing technology. It is intended that this will lead on to a larger Collaborative R&D project that will look into potentially developing new alloy compositions that could be manufactured at Ebbw Vale, leading to increased annual revenue in excess of £1 Million for the plant.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Blaenau Gwent

Status: Completed

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Envirowales Limited recycle scrap lead acid batteries at their manufacturing base in Ebbw Vale. The lead is being recovered and purified and then sold into markets that include construction and electrowinning anode manufacture.
For electrowinning applications, rolling the cast lead alloy to the desired thickness enhances the mechanical characteristics of the anode. However, it may be possible that the elongated nature of the grains that result from rolling may make the anodes susceptible to corrosion in certain circumstances. So the company would like to optimize the rolling procedure and tailor the anodes to specific electrolyte scenarios.
For the proposed project, the Swansea University ASTUTE 2020 team will examine the structure and properties of a range of different rolled samples using material prepared by Envirowales. Enhancing rolling parameters is expected to improve both the mechanical and corrosion performance of the manufactured anode.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Blaenau Gwent

Status: Ongoing

Flamgard‐Calidair manufacture high specification heating, ventilation and air conditioning (HVAC) dampers and associated equipment for the global oil and gas, nuclear, marine, power generation, tunnel and metro and industrial sectors.
Flamgard‐Calidair are working towards developing improved products meeting tighter specifications with the aim of being able to increase their market share within the nuclear sector, which is demanding tighter specifications.
This project will focus on research using computational modelling of the damper systems to enhance the performance of the dampers in terms of integrity, insulation and leakage after prolonged exposure to a fire.
This research will allow Flamgard‐Calidair to produce more advanced damper systems to meet current and future demand, allowing the company to remain at the forefront of this market.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Torfaen

Status: Completed

Ford’s Bridgend Engine Plant employs over 1,800 people and produces 634,000 petrol engines per year, with plant turnover around £1billion per annum. In addition to the assembly of engine components there is extensive machining work on cylinder heads and engine blocks using automated cutting machines. Improvements in machining productivity are a high priority.

The objective of the research project is to develop a better understanding of the flow characteristics of the cutting fluid used in the machining operation and how it interacts with the surrounding pipework that transfers it to and from the cutting machines. The work will utilise Swansea University’s expertise in Computational Engineering Modelling. Expected outcomes are enabling the company to ensure durability of the fluid transport system. Impacts in the longer term will be to inform future decisions on the spatial layout of new pipework.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Bridgend

Status: Completed

This project will investigate what is needed for Ford to effectively monitor manufacturing materials delivered to their Bridgend engine plant. It will explore the technical, managerial, and commercial issues involved in deploying such a monitoring system, and produce recommendations for how a full system could be developed.

Expertise: Manufacturing Systems Engineering

Academic Partner: Aberystwyth University

Location: Bridgend

Status: Completed

Frontier Medical, based in Blackwood, is one of the leading suppliers of consumable products and services to healthcare providers. The company has established a dedicated team to develop a plan to enhance its injection moulding operations in order to improve profitability, productivity and product quality. The Frontier Medical team is seeking ASTUTE 2020 help and advice to develop a procedure to achieve this goal.

The team has identified that selection of the processing parameters is empirical and based on operators’ previous experience. By gaining a deeper insight into the fundamental physical practices involved in the injection moulding process, the company feels it can make substantial savings and improvements, anticipating a lower energy usage, a lower material usage and costs, reduced cycle times, an improved product quality, and a systematic production monitoring and management control system, all of which can enhance profitability.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University 

Location: Caerphilly

Status: Completed

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As toolmakers, FSG Tool & Die Ltd (FSG) has designed and built manufacturing systems for market leading manufacturers for the last 30 years, including the design of pressing tools for the process industry.

FSG are seeking ASTUTE2020 team academic expertise to significantly improve the performance of the press tooling components used in the manufacture of standard and smooth wall, round and irregular aluminium foil containers, for applications such as take-away food, frozen foods,desserts and airline meals.

This collaborative research aims at developing forming tools to effectively produce aluminium foil trays consistently, minimising the appearance of unsightly defects. With the current moulds, these defects frequently occur at the corners of the upper surface of the tray as the sharp edge of the tray is being folded, resulting in buckling/wrinkling at these corners.

It is expected that the collaboration will open up the possibility of the development of a 2 compartment tray. This would be a significant step forward in packaging & tool design, giving the company a leading edge over its competitors, with a direct impact on company investment, profit and increased workforce.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Status: Completed

Location: Rhondda Cynon Taf

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FuelActive Ltd is a global leader in providing solutions for diesel fuel contamination problems in engines and fuel storage units. The company is based in Taffs Well and has been trading since 2006. FuelActive currently operates in the diesel power unit markets in the fields of construction and mining, transport, power generation, marine, agricultural and military.
This project is aimed at the use of Computational Fluid Dynamics to assist in the development and optimisation of FuelActive’s novel fuel cleaning units which are designed for large‐scale fuel storage units. Computational modelling will provide insights into the behaviour of different contamination constituents, and this information will be used in the device optimisation.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Cardiff

Status: Ongoing

Gomer press have a monitoring system that records production on each machine in the plant.
They wish to archive that historical data and then use it to streamline the business by optimising the workflow on the machines.
To have this in place would create a job for an assistant bindery/production manager, because it would give us the means to start to step back from day to day production concerns and manage longer term trends and individual and machine performance.
It would also definitely also help safeguard jobs because it is a vital tool to help manage performance in a simple way that is not currently possible, but definitely necessary.

Expertise: Manufactuirngsystems Engineering

Academic Partner: Aberystwyth University

Location: Ceredigion

Status: Completed

Hackwood engineering manufacture piping assemblies that replace conventional concrete reinforcement. This solution provides simplified assembly and reduced environmental impact compared to concrete reinforcement.
This project will use computational analysis to assess the structural integrity of the assemblies, including their interaction with the surrounding soil. Additionally, the potential to recover the assembly at end‐of‐life, to recover and recycle the materials used will be explored.
As a result, Hackwood will gain a better understanding of their product and be able to provide further engineering details to prospective customers expanding their marketbase. Additionally, recovery of end‐of‐life products will further reduce the environmental impact of the product and recycling of material from end‐of‐life products will improve the economics of the process.

Expertise: Advanced Materials Technology, Computational Engineering Modelling & Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Newport

Status: Ongoing

I‐Photonics Ltd is developing a Light Emitting Diode (LED) based flexible silicon cap for Low Level Light Therapy (LLLT). The device is made of a stretchable and highly flexible material which allows application to curved or rounded surfaces. All current offerings are either rigid or semi‐rigid.
This device is affordable and is battery operated an it delivers the optimum wavelength; its design allows for better contact with the tissue due to its flexibility
The computer modelling will help to establish what the optimum energy (total dose) should be, by allowing us to see where within the tissue this wavelength is mostly absorbed.

Expertise: Computational Engineering Modelling

Academic Partner: University of Wales Trinity Saint David

Status: Completed

IrvinGQ is a market leading business developing and manufacturing naval decoy systems, aerial delivery equipment and personnel parachutes, primarily for the military market. Its customers include the UK MoD and US DoD, Martin Baker, as well as many Tier 1 aerospace suppliers.

IrvinGQ have developed many parachutes using empirical design principles and extensive testing programmes to ensure that parachutes meet the required performance characteristics. Physical testing is an expensive and time-consuming process and IrvinGQ want to research the validity of using more computational simulation in their parachute development process. This project is to develop a simulation methodology and to test the validity of using computational models to predict parachute performance by comparing simulation results with experimental results.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Bridgend

Status: Ongoing

James Technical Services Ltd (JTS) is an independent specialist manufacturing company that produce high quality refrigeration products, electrical control products and packaged control room systems. Since 1995, the company has served a wide variety of industries such as aerospace, automotive, defence, marine, off‐shore and pharmaceutical companies.

One of the refrigerants used by the company (R23) is due to be phased out due to its high impact on the environment. In order for the company to meet the new requirement and keep the same level of competence they currently have, JTS needs to find an alternative working medium that delivers the same thermodynamic performance with less impact on the environment.

The ASTUTE EAST team has been tasked with identifying an alternative refrigerant that meets these requirements by searching in the available literature and patents databases. Alternatively, this project will attempt to identify the properties required of a substitute refrigerant. If this search is not conclusive, the ASTUTE EAST team will focus on ways of mixing existing components (including R23) by analysing phase diagrams to achieve required properties.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Powys

Status: Completed

This project involves experimentation and Computational Fluid Dynamics (CFD) analysis of fluidic chip nozzles. The primary aim is to investigate the performance of two nozzles, designed by the company, through high-speed photography and CFD analysis. The secondary aim is to increase the understanding of fluid  flow within such nozzles to allow nozzle performance characteristics to be met through geometry changes.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Caerphilly

Status: Completed

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The Knight companies based in Cardiff are a leading plastic moulding company that in addition to trade moulding produces a range of own labelled security projects. There is also a sister company based in Wales that manufactures plastic injection moulding tools. The assembly of their components is not high volume but has high variability and requires 100% testing of the finished products. The company wishes to explore methods by which automation can improve productivity and consistency.
This collaborative research project will assess the feasibility of introducing collaborative automation techniques to a current production line. This could help to reduce the pressure on workers by taking over repeatable work. Introducing collaborative robots to the production line, the inspection outputs from a robot are easily accessible, providing the company with quantitative data, analysis of which will lead to continual improvement. The repeatability of a collaborative robot will also help to reduce variability on key assembly tasks.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Cardiff

Status: Ongoing

Ledwood Mechanical Engineering (LMEL) core competence and main skills include engineering, fabrication, protective coatings and construction. Since LMEL operates in competitive and commercially sensitive sectors and markets whilst being financially sustainable, LMEL needs to increase its productivity by promoting cost reduction engineering excellence.
As part of an operational excellence initiative, LMEL requires a study of its current manufacturing facilities and processes to determine how best to apply innovation for operational improvements and to promote a competitive advantage that can be vertically integrated within its business.
The technical work of this proposed ASTUTE2020 project will include data collection and analysis to determine how innovation can provide improved working practises and facilitate new technology deployment.

Expertise: Manufacturing Systems Engineering

Academic Partners: Swansea University & Cardiff University

Location: Pembrokeshire

Status: Completed

Lyte Ladders & Towers Ltd., “Lyte”, was established in 1947 and is based in Swansea, where it manufactures an extensive range of high-performance steps, ladders, towers and bespoke access equipment for domestic, trade and industrial users. To meet enhanced customer requirements and to comply with new legislative European standard, the company plans to introduce a new range of products with superior performance attributes.

Lyte is, therefore, looking to collaborate with Swansea University’s ASTUTE 2020 team to use computational modelling to research the variation of mechanical stresses within its ladders and access equipment. This will include a comparison of new emerging materials (e.g. advanced composites) against more traditional materials (e.g. aluminium). The University’s electron microscopes will also be used to gain an understanding of microstructural changes resulting in the material failure.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Swansea

Status: Completed

Know Previously as Lyte Industries (Wales) Ltd.

Lyte Ladders & Towers Ltd., manufacture an extensive range of high performance steps, ladders, towers and bespoke access equipment for domestic, trade and industrial users. To meet enhanced customer requirements for products with superior performance attributes, Lyte has recently invested around £300K in a state‐of‐the‐art Robotic welding platform for aluminium.

The company is seeking ASTUTE2020 help to improve the weld quality using the robotic process by researching the optimisation of the weld process, including the pre‐process set‐up and the implementation of closed loop vision guided control of the robotic welding platform.

Phase I will cover pre‐welding set up, and provides recommendations for best practices to avoid impairment of the process. Phase II will be deal with the optimisation of the weld parameters in the robotic welding cell. Phase III will consider an advanced computational modelling simulations to advise on the optimum welding processing conditions in terms of welding speed, power and angle, thermal conditions and welding path.

The outcome of this research project will be to improve Lyte production technologies and products through the use and integration of smart robots and sensors technology. In addition, the collaboration work will result in an extensive knowledge transfer and understanding of the robotic welding platform to both parties.

Expertise: Manufacturing Systems Engineering, Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Swansea

Status: Completed

Know Previously as Lyte Industries (Wales) Ltd.

Marine Power Systems, based in Swansea, is developing a wave energy converter device that addresses the many challenges of extracting wave energy at an acceptable cost.

A critical component of the device is a continuously wound glass reinforced plastic float, to be manufactured by a local composite specialist. Computational research of this component will allow Marine Power Systems to assess the suitability of the design and significantly de-risk the build and test stage of the project. As a composite material is being used, specialist analysis techniques are required that were not found in the local supply chain.

ASTUTE 2020 will create suitable computational models of the component using information supplied by Marine Power Systems and run finite element analysis on the structure.

The results of this project will allow confidence that the design is fit for the intended application (a world first) and highlight any improvement that could be made to the full-scale device.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Swansea

Status: Completed

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Markes International, headquartered in Llantrisant, RCT, is one of the world leading developers and manufacturers of scientific instruments for thermal desorption and time of flight mass spectrometry. In 2015 it won a Queen's Award for Enterprise in the “International Trade” category and in 2019 it has again won the Queen’s Awards for Enterprise, in the categories of ‘Innovation’ and ‘International Trade’.

Products designed and manufactured by Markes are used in a variety of application areas, including:

• Environmental monitoring – the detection of hazardous chemicals in air, water and soil
• Security detection of chemical warfare agents; material emissions
• Food analysis quality control & safety
• Fragrance and aroma profiling
• Geochemical and petrochemical fingerprinting
• Environmental forensics; breath sampling for disease diagnosis
• Metabolic profiling

The ASTUTE 2020 collaborative research project is aimed at expanding valve capability to meet the market needs of the future through innovative research into material science and engineering. The outcomes will continue to drive Markes’ annual 20% growth.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Rhondda Cynon Taf

Status: Completed

Markes International, headquartered in Llantrisant, RCT, are one of the world leading developers and manufacturers of scientific instruments for thermal desorption and time of flight mass spectrometry. In 2015 it won a Queen's Award for Enterprise in the “International Trade” category.

Products designed and manufactured by Markes are used in a variety of application areas, including:

• Environmental monitoring – the detection of hazardous chemicals in air, water and soil
• Security detection of chemical warfare agents
• Food analysis quality control & safety
• Fragrance and aroma profiling
• Material emissions
• Geochemical and petrochemical fingerprinting
• Environmental forensics
• Breath sampling for disease diagnosis
• Metabolomic profiling

There is a growing demand for this technology and Markes has successfully positioned its product range to capitalise in this market for several years. The current work will play a critical role in the company meeting its 2020 growth targets, through enhancing the resilience of their manufacturing systems and supply chains.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Rhondda Cynon Taf

Status: Completed

Abstract:

Cross-linked polyethylene (XLPE) is widely used as an insulant in the manufacture of medium and high voltage electric cables and its manufacturing process creates waste material that is disposed of in landfill. A large XPLE plant exists in east Wales, and Marlin Industries Ltd provide it with a range of support services including the recycling of plastics. They wish to divert XPLE from landfill to a reprocessing route that will create feedstock material for a commercially viable product.

The project aims to identify mechanical or chemical treatments suitable to modify or reverse the cross-linking process to create a grade of polyethylene that would be suitable for reprocessing & recycling.   

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Wrexham

MEDuCAN ltd is an SME, based in East Wales, aiming to position itself at the forefront of agricultural manufacturing technology. The company plans to cultivate local agricultural expertise and to rejuvenate and revolutionise farming in Wales by establishing a centre of excellence for Aeroponic Vertical Farming and Agrimetrics, thereby relocating agriculture from the field into the factory. Current political and environmental challenges – including Brexit, the COVID crisis and the climate emergency – underline the shortcomings in Welsh agriculture and highlight the opportunities for improvement. Wales must boost domestic food production and reduce reliance on imports.

This collaborative R&D project will explore intelligent manufacturing systems, applicable to the farming sector, as well as innovative applications for agricultural data to optimise the growing process and to advance intelligent systems in agriculture, akin to Industry 4.0. This will aid MEDuCAN in exploiting such processes commercially and for the benefit of Welsh farming. It is anticipated that this project could indirectly provide significant benefits to farming communities across Wales. This will be in addition to advancing agricultural manufacturing processes and pushing Welsh agriculture towards the forefront of Agriculture 4.0.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Rhondda Cynon Taf

Status: Ongoing

Abstract:

Micro Materials are a world leader in nanomechanics and are working with ASTUTE to improve indenter bonding and hot stage performance so that nanomechanical tests can be performed reliably at high temperatures (up to 1200 degrees centigrade).

The project involves developing advanced instrumentation for measuring mechanical properties of materials at small scale and elevated temperatures. This will be achieved by utilising ASTUTE EAST’s expertise in materials science and advanced computational modelling.

The success of the project will allow Micro Materials to extend the maximum temperature in its NanoTest Xtreme high temperature vacuum nanoindenter, and to test the mechanical properties of materials used in aerospace, energy, and high-performance machining sectors at close-to operating temperatures.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Wrexham

A Composite Material is a material made up of two or more materials woven or mixed to make a new material that has better strength and or reduced weight. Traditional examples include concrete and plywood. Modern advanced composites (carbon fibre, reinforced plastics, Kevlar) are increasingly being used in many applications such as aircraft, vehicles and crash helmets. Their benefits (corrosion resistance, weight advantage, strength) are well documented; however, composite material damage is more difficult to identify compared with equivalent metallic structures. This is particularly relevant when composite materials are used in safety‐critical systems, for example, suspension components, airframes and safety helmets. Impact damage or wear is often inside the material making it invisible on the surface and raising the question; how to know that a crash helmet or suspension system is still safe to use?
In this project, the aim is to develop a cost‐effective sensor system to monitor and detect the formation of invisible cracks and wear and hence increase product safety and maximize end of life. The Project involved end‐user original equipment manufacturers (OEMs) from non‐competing industries all looking to make more use of composite materials in their product.

Expertise: Manufacturing Systems Engineering & Advanced Materials Technology

Academic Partner: Cardiff University

Status: Ongoing

Moulded Foams Ltd. and DB Mouldings have been supplying Champion Manufacturing for many decades with moulded outer shells and foam linings which they incorporate into their top quality riding helmets. Helmets are manufactured to exacting standards and the designs and standards have evolved over many years.

A new standard will be introduced shortly and although Champion are confident they can meet these standards they consider there is a bigger opportunity to review their design performance using advanced computational modelling techniques and incorporate high value manufacturing methods which are now available. Helmets are manufactured in a range of sizes and there is a complex interaction between the outer shell, foam liner and the head. This collaborative project will utilise the skills of all companies and Cardiff University to research this problem and to improve helmet performance and manufacturing methods.

Lessons learnt by the research team can also be applied in crash protection systems typically for the automotive sector.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Cardiff University

Location: Blaenau Gwent, Cardiff, Merthyr Tydfil

Status: Completed

Northern Automotive Systems is a world leader in the manufacture and supply of decorative aluminium trim for the automotive industry. NAS is part of the NBHX Trim group and their customers include premium OEMs (JLR, PSA, Bentley, Rolls Royce, BMW, VW, Audi, & Volvo) and well‐known Tier‐1 Suppliers within the automotive industry.

NAS want to become more efficient in their use of raw materials in their coating process. NAS have identified that improving the yield from their coating process will allow them to achieve significant efficiency improvements. In order to achieve these efficiency imrovements NAS need to increase their understanding of some aspects of their coating process. Through greater understanding of their coating process NAS believe they will be able to implement process improvements that will result in more efficient use of their raw materials, allowing them to reduce their costs. Ultimately this will allow NAS to remain a leader in the decorative aluminium trim automotive supply chain, and will allow them to become more competitive within their market / industry field.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Monmouthshire 

Status: Ongoing

Ortho Clinical Diagnostics manufactures medical tests using advanced manufacturing technologies including robotics. In order to maximise production efficiency they wish to conduct collaborative research on the effects of varying dispenser nozzle shape and the method of machining employed on the accuracy of a robotic process. The research techniques to be used include Micro Electrodischarge Machining, Laser Anemometry and high-speed video imaging.

The objectives of the project include, the production and testing of prototype dispensing nozzles in a laboratory environment and transfer of the knowledge gained into the manufacturing environment. The impact of the project will be to increase production efficiency and support increasing the number and scale of products manufactured at the facility.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Bridgend

Status: Completed

PE Site Solutions provide specilaist expertise and services for construction projects utilising High and Medium Density Polyethylene (HDPE & MDPE). They have expertise in extrusion jointing and onsite welding and fabrication of pipe systems and structures manufactured from these materials. They also provide independent inspection, supervision and training services.

HDPE and MDPE structures are being widely used in the water management industry, and are often sufficiently large that they need to be constructed on site. PE Site Solutions provides the expertise in jointing and onsite welding needed to manufacture these systems.

PE Site Solutions want to have greater scientific understanding of HDPE extrusion jointing processes. By having a greater scientific understanding of their welding processes they will be able to offer their customers enhanced services and improve the quality of the systems they manufacture. Improved scientific understanding will allow PE Site Solutions to improve their processes, which will increase their ability to manufacture systems more quickly, with higher quality and reduced wastage.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Torfaen

Status: Ongoing

Perpetuus Carbon Technologies is an advanced nanomaterial manufacturing company in South Wales. The company specialises primarily in surface engineered carbon and graphene nanostructures.

This aim of this project is to design novel polymer materials, which provide visco-elastic properties required for the design of a lower limb prosthetic foot or orthotic devices, with the additional constraint of enhancing material properties at costs lower than the existing prosthesis/orthosis feet. It is hypothesised that graphene reinforced polymers have the potential to meet this challenge. This material is also potentially suited for 3D printing, which allows for customised prosthesis foot design. The objective of this project (in its initial phase) is to undertake a feasibility study on whether graphene-based polymers can be designed at a micron level in order to deliver the demanding properties that the prosthetic or orthosis may require in term of flexibility and strength. The project will proceed and iterate in three steps: (I) the design of a/the graphene reinforced microstructure; (ii) the manufacture of samples for mechanical testing by injection moulding; and (iii) the mechanical characterisation of the novel material.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Carmarthenshire

Status: Completed

Perpetuus Advanced Materials (“Perpetuus”) is an advanced material manufacturer primarily focused on surface engineered carbon structures such as graphene and carbon nanotubes.
Perpetuus has developed and is commercialising a process for producing industrial scale, cost effective, surface engineered Advanced Materials, commencing with graphene.
The project will provide detailed analysis on the impact of graphene on the mechcanical and physical properties within a polymer matrix, this can include thermosets resins, thermoforming resins and elatomers . The use of computer model will provide assiatnce in deciding the type of Graphene, surface functionality,loadings and morphology best able to provide certain properties. This can then be validated by performing the practical tests

• Theoretical outcomes of polymer matrices
• Theoretical outcomes of polymer matrices with Graphene
• Outcomes validated by practical testing

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Carmarthenshire

Status: Completed

At Procter we supply and install many types of acoustic fencing / screening ranging from steel, timber and over the past 4 years recycled plastic.
Our sales and demand is very strong for the recycled plastic due to the environmental impact as well as the lifespan of the product. However, although we have a supplier for this product in Bristol they cannot service our needs or demand meaning we have had to stop offering this product to the market.
This collaboration with ASTUTE2020 opens new opportunities for Procter in identifying a sustainable recycled material that provides enhanced mechanical and acoustic performance panels. It is also aimed at reviewing the manufacturing process of this board and selecting a local or national manufacturing company who would manufacture this for them in the future.
The technical work will be in collaboration with ASTUTE2020 for the components and the outcome would be boost in sales and employment if we are able to secure a reliable source of this material.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Caerphilly

Status: Completed

Pro‐Flow Solutions are a small entrepreneurial company based in Tredegar, Gwent. They currently manufacture and sell a device which turns off the water supply when a leak is detected. This device was originally developed with assistance from the ASTUTE project. They now wish to develop a “Smart” version of the product that customers can interact with. The project will involve:

• Construction and testing of a system to store and manage data.
• Construction and testing of a system to allow customers to interact with the device via the IOT.
• Assessment of whether sample data from existing devices can be used with machine learning.

A Smart version of the product will significantly widen the market for the device and lead to increased job opportunities and investment in manufacturing the product in WWV.

Expertise: Manufactruring Systems Engineering

Academic Partner: Cardiff University & Aberystwyth University

Location: Blaenau Gwent

Status: Ongoing

Qioptiq is a global leader in the design and manufacture of products for a range of high value manufacturing sectors including defence, aerospace, and medical and life sciences. A core strength of the company lies in its Research and Development capability and the application of this capability to collaborative projects with Higher Education Institutes.

Qioptiq's products operate in challenging environments often subjected to extreme temperatures and loads. The shock loads involved in some applications are unprecedentedly high and can result in damage to sensitive electronic sensors and components within a product. Qioptiq approached ASTUTE to develop an innovative solution to mitigate the severe loads transmitted to the components within a product by exploiting the complex lattice design and advanced materials afforded through the use of additive manufacturing and computational modelling. The proposed concept is unique, a feasibility study proved the approach to be highly effective offering significant potential to generate new IP. The development work will not only produce a functioning prototype but contribute to the knowledge required to design and analyse such components.

As a minimum, it is anticipated that the development work will increases company revenues by £1 million per annum and require additional skilled personnel to be recruited.

Expertise: Advanced Materials Technology & Computational Engineering Modelling 

Academic Partner: Cardiff University

Location: Conwy

Status: Completed

This project aims to support the construction of a fully functioning Additive Manufacturing (AM) system also referred to as a 3D printer, which is capable of printing with energetic (explosive) materials, and the production of a computer model for simulating detonation wave behaviour from 3D printed charge parts.
Traditional methods of manufacturing energetic products involve using cast-made moulds, the shaping of which is not exact, with many iterations needed. This process is extremely wasteful, as the moulds are not adaptable, taking considerable time for production and any amendments. There are also limitations to the shape of the mould, as at the end of the process the tooling must be removed.
The ability to use AM removes these complexities and, only now, do sophisticated geometries become easily accessible. AM requires no expensive tooling or heavy infrastructure, the parts are fabricated layer by layer, and the restrictive nature of trapped components from cast-made designs is no longer an issue. The economic barrier to research is lowered and access to this field by a wider cohort including academics and SMEs is now possible. The design and experimentation life cycle is greatly shortened leading to faster innovation and product development.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Powys

Status: Completed

Radical Materials Limited are a small innovative company with plans for expansion. They are market leaders in the manufacture and supply of antimicrobial additives for incorporation into polymers, paint coatings, rubber and silicone. Radical Materials has significant technical expertise and experience in material engineering, particularly polymers, and wishes to conduct collaborative research with Cardiff University into the formulation, extrusion and testing of plastics with novel characteristics, anti-microbial and other characteristics. The aim of the project is to characterise samples of novel polymers with a high potential for industrial applications.

Expertise: Advanced Materials Technology

Academic Partner: Cardiff University

Location: Blaenau Gwent

Status: Completed

Formally known as SteriTouch Ltd.

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ROOF (the product) is a water‐resistant insulated all in one padded coat with an integrated sleeping bag, hood, hidden pockets and composite (multi‐layered) interlining ‐ designed to pack‐away into a cross over lightweight and portable shoulder bag.

The sleeping system is still at its early stages (prototype) and its development is focussed on delivering a final product to be used as a rapid response device to provide shelter to refugees or those suffering from homelessness. Due to the modular nature of the system its applications will eventually extend to Armed Forces sniper units. It will be understood how these applications involve multiple/diverse and unpredictable environments in which the garment properties will be the key factor affecting comfort.
UWTSD will be involved actively in the research and development of procedures including both conventional and non‐destructive tests to ensure the performance of ROOF fits most extreme conditions. It must be mentioned that such a product is both a sleeping bag and a coat for which current standards are only defined individually.

Expertise: Advanced Materials Technology

Academic Partner: University of Wales Trinity Saint David

Location: Swansea

Status: Completed

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Formally know as Red Dragon Manufacturing Ltd.

Reid Lifting are based in a recently built new £4m factory on the Newhouse Farm Industrial Estate, Chepstow. They have been awarded the prestigious Queen’s Award three times for Enterprise Innovation for their innovative design and development of lightweight, portable and safe lifting solutions in 2006 and 2013. Recently Reid Lifting were the winners of the ‘Excellence in Export & International Trade’ award at the Monmouthshire Business Awards 2017.

Examples of applications of Reid Lifting equipment include:

• Water and wastewater treatment
• Hire/rental
• Handling and storage markets
• Renewable energy (wind turbines)
• Oil and gas (including offshore) with ATEX certification
• Nuclear industry
• Automotive
• Civil engineering
• Utilities
• Art galleries, museums and exhibition centres
• Health
• Transport services
• Maintenance services
• Confined space and work at height (with PPE Directive EN795 certification)

There is growing international demand for the equipment and Reid Lifting has successfully positioned its product range to capitalise on this market for several years. The work will play a critical role in the company meeting its growth targets, through enhancing the robustness of their forecasting, inventory and manufacturing systems.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Monmouthshire

Status: Completed

Riversimple, based in Powys, is developing affordable hydrogen fuel cell cars, to be provided as a mobility service, rather than a product. One monthly payment, with a fixed monthly fee and a mileage rate, will cover everything, including fuel, so efficiency and light weight are paramount. In low volume production, (currently 20, plans for 5,000pa) processes such as Additive Layer Manufacturing (ALM) are feasible manufacturing routes. This project will explore the feasibility of using these techniques to manufacture the Swan Neck Door hinges. Riversimple have already explored alternative manufacturing techniques, none of which have presented a viable production ready solution.

Technical Work: Riversimple will supply the load cases for the door/hinge arrangement and the design domain, as well as the CAD for the current hinge. The ASTUTE team will use topological optimisation techniques to minimise weight whilst maintaining the required mechanical strength and functionality. A hinge with optimised geometry will then be manufactured using ALM. The component will be assessed to validate strength and accuracy.

Outcome: An optimised door hinge and the assessment of ALM as a viable manufacturing route.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Powys

Status: Completed

RPC-bpi is part of the RPC group, a multi-national company. RPC has extensive manufacturing facilities providing a truly global reach, supporting customers worldwide. RPC sites offer expertise in a variety of technologies and end markets, delivering a wide choice of plastic packaging solutions.
RPC-bpi recycled products is the leading polythene film recycler in Europe. The recycling centre in Rhymney, Gwent can process up to 20,000 tonnes of waste polythene from commercial, industrial and agriculture packaging. The plastic is collected, washed and then palletised to provide feedstock for a range of recycled products e. g. refuse sacks, damp-proof liners, garden furniture and fencing.
The proposed project focuses specifically on the Plaswood product, a recycled plastic lumber that is currently used for street furniture, signage and decking. The product is 100% recyclable and made predominantly from a blend of waste coming from post-consumer, industrial and agricultural sectors. Through experimentation and computational modelling new blends of recycled substrate and fillers will be investigated to improve Plaswood’s properties and extend its range of use and thus broaden the potential market for the product.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Caerphilly

Status: Ongoing

Safran Seats UK, the second largest aerospace company in Wales, assembles high quality passenger seats at their facility in Cwmbran. The manufacturing process for the seats is a vacuum bag/autoclave moulding technique, using glass pre-impregnated fibre/phenolic composite fibres.

The proposed R&D collaborative project centres around identifying alternative manufacturing technologies to create prototype tooling for composites and associated limitations for such tooling. The investigation will address the generation of a prototype tool design from a CAD model; Potential pressure/temperature limitations of the tooling; The cleaning and resin resistance of tool materials; Identifying techniques by which prototype tooling could be created; Determining potential costs and comparisons to production tooling; Estimating manufacturing lead times for such tools.

With the present collaborative research project, Safran Seats would like to investigate alternative manufacturing technologies for the tooling. For prototyping, in particular more rapid manufacture would allow the tool to be ordered closer to the final design iteration of the product and thus would require fewer modifications and reduce the development and tooling costs.

Expertise: Computational Engineering Modelling and Advanced Materials Technology

Academic Partner: Swansea University

Location: Newport

Status: Completed

Know Previously as Zodiac Seat UK Limited

Abstract:

Additive manufacturing is making an entry into aircraft interior products. Within Safran we have qualified the Stratasys FDM ULTEM 9085CG process and material for non‐structural applications. To broaden the business AM capabilities were now maturing the SLS technology with PA2241FR powder. At entry to the project the technology is at TRL3 maturity. The project entails testing and validation of machine, material and product characteristics with the support of Swansea expertise. Manufacturing will be performed with virgin powder as well as several mixed, virgin and used, powder to determine the effect of recycling loops on mechanical, flammability or quality properties of the product. The outcome of the collaboration project will be for the Safran project team to gain expert insight and understanding on validation of material testing results, identification of process monitoring parameters and to obtain the maximum viable recycling loops for the powder material based on batch testing.

The support of Swansea will accelerate the project to more efficiently assess results and make non‐bias decisions to finally pass TRL5. The application of AM on seat shells, especially business and first class, will contribute to an efficient supply chain, reduced lead time, cost and weight to the final product.

Expertise: Advanced Materials Technology 

Academic Partner: Swansea University

Location: Torfaen

Status: Ongoing

H-X nickel based alloy has been widely used for high temperature and corrosion resistance applications, and is also commonly employed in gas turbine operations. Sandvik Osprey produces ‘conventional’ H-X powder for metal cladding applications. Despite the potential benefits behind using H-X powder for Additive Layer Manufacturing, this fabrication route is currently hampered due to microcracking of the material.

The project aims to research this specific microcracking issue by alloying the H-X powder prior to Selective Laser Melting operations. In addition to the overall aim of microcracking elimination; the project will also focus on the comparison of mechanical properties before and after the H-X powder modification and the development of a methodology for introducing the H-X powder and alloy mixing process into production.

The collaborative research will assist the company in developing advanced H-X powder suitable for metal additive manufacturing.

Expertise: Advanced Materials Technology & Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Neath/Port Talbot

Status: Completed

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Seminar Components design and manufacture lift and recline chair mechanisms for the health care industry. Market research has identified an increasing demand for bariatric chair mechanisms with greater weight capacities. In order to overcome the challenges in manufacturing such mechanisms, the use of alternative materials will be investigated, along with a more detailed analysis of material behaviour such as fatigue performance and formability using finite element analysis. In addition, research will be conducted into the feasibility of using a computational optimisation method to determine an optimum reclining mechanism geometry given a set of system constraints. This more detailed analysis will allow Seminar Components to produce more advanced precision action seat mechanisms to meet current and future demand, allowing the company to remain at the forefront of this market.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Swansea

Status: Completed

This project is to conduct research into transient magnetic phenomena to assist in the understanding of the magnetic fields induced during magnetic flux leakage non‐destructive testing. The aim of the project is that the understanding gained will assist the company in making future product enhancements to their magnetic flux leakage NDT systems.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University & University of Wales Trinity Saint David (UWTSD)

Location: Swansea

Status: Completed

Spectrum Technologies is a world leader in the design and manufacture of specialised state‐of‐the‐art industrial laser systems. The Company has its headquarters in Bridgend, Wales, UK where it undertakes design and manufacture of all of its products. The Company was started to undertake the commercialisation of laser technology derived from BAE’s R&D programmes which did not fit with the business of its main operating divisions. The company was established in 1989 as a wholly owned subsidiary of British Aerospace PLC (now BAE Systems PLC), as a spin off from BAE’s corporate R&D centre in Bristol, UK. The Company sells its products primarily direct to its business customers in North America and Europe and through distributors and agents throughout the rest of the World, in particular Asia Pacific.

The proposed ASTUTE 2020 collaborative research aims to prove and demonstrate that the process of laser wire stripping has no detrimental effect on the electrical and physical properties of the wire or cables used in the Aerospace Industry, in particular on the conductors (Aluminium and copper plus nickel and silver plated conductors). It is also scoped to understand the effects the laser has on the polymer insulation (FEP, ETFE, PTFE, KAPTON and PVDF) and how to minimise carbonisation and other thermal affects.

In the proposed research, two type of laser stripping technologies are considered: the CO2 10.6μm laser wire stripping and an alternative laser wavelength (e.g. 445nm). The focus will be on the CO2 laser wire stripping to demonstrate it suitability to be an approved process with the major Aerospace OEMs (Airbus, Boeing). To date there have been no in depth studies into the effects of the laser on the conductors, nor any attempt to research ways of minimising the carbonisation found on some wire types.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Bridgend

Status: Completed

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SPTS Technologies, a KLA company, designs, manufactures, sells, and supports etch, PVD, CVD and MVD capital equipment, providing advanced wafer processing technologies and solutions for the semiconductor and microelectronics industry. End‐market applications include micro‐electromechanical systems (MEMS), advanced packaging, LED, high speed RF device IC’s and power semiconductors.

The Proposed Astute project will look at how robust the manufacture of the electrostatic chuck (ESC) is and why a high rate of failures are seen with cracking to the bonded alumina plates. The hypothesis is that the ceramic cracks are due to thermal expansion or contraction when the ESC is heated or cooled at a rate higher than 1oC per minute. Cracks have propagated very early life (ESC start‐up) and mid‐life (>2000 process hours), and are normally indicated by an electrical breakdown of the ESC. SPTS need to understand why this occurs as the impact is a very high churn rate of spares (some FOC) that constricts the ability to supply. The methodology dicussed is to create computer model of the ESC to replicate what is happening, confirm that failure more in a real world trial and conduct an FMEA analysis of the part and its manufactre to reduce or eliminate the failure modes we see.

Expertise: Advanced Materials Technology, Computational Engineering Modelling, and Manufacturing Systems Engineering

Academic Partner: Swansea University, Cardiff University, and University of Wales Trinity Saint David 

Location: Newport

Styrene Systems Ltd is a small SME, based in Pembrokeshire, which manufactures and sells machines that compact waste plastic foam packaging such as Expanded Polystyrene (EPS), Polypropylene (EPP) and Polyethylene (EPE).

The machines use auger technology to remove air from the foam by either mechanical pressure (Compaction) or both heat and mechanical pressure (Densification). The resulting processed material is dense, has a commercial value and can be re‐used in the circular economy.

The proposed collaborative research project will examine the various processes that the foam plastic material undergoes such as: shredding, heating and a mechanical compacting process, and their interactions. The aim is to optimise this technology or to create another novel methodology to solve problems inherent in the original approach. An experiment based statistical analysis of the machine process elements and parameters will define the importance, the relevance and the impact of changes on individual stages of the total process.

Additionally, the company is seeking some guidance in building upon this knowledge to create an advanced computational model of the total process to enable parameters to be optimised without the need to manufacture a large number of trial machines. The latter approach will be developed outside ASTUTE 2020 scheme or in a separate project phase.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Pembrokeshire

Status: Completed

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SunScape’s primary innovation “Carapace Slate” is a recycled, low-carbon slate composite roof tile with a novel snap-fit fitting assembly that deskills installation and increases worker productivity by over 90%. The collaborative ASTUTE East and SunScape project (CASCOM) aims to develop advanced predictive capabilities towards the current in-house composite slate production process. Preliminary experimental studies have identified workable boundary conditions towards slate production on batch-scale with conformity to relevant BBA/BS standards. Practical experimentation has broadly determined key operating variables such as raw materials composition, epoxy formulation and curing conditions. However, such trial-anderror methodology, though successful, is time-consuming and needs to be supported by robust computational models that can help elaborate scientific understanding and the underlying mechanism involving chemical and physical transformation stages.
The computational models (Structural and CFD) could help identify how the slate and the material properties behave (physical, chemical, thermal) to obtain part strength and rheological information. The predictive model backed with key inputs (experimental findings) from SunScape could then be able to validate the modelling results for practical use during high-volume manufacture. The company will ultimately be able to develop a commercial infrastructure which is reactive to an ever-changing market, by implementing a dynamic and repeatable ‘Smart’ manufacturing solution capable of rapid global growth.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Cardiff

Status: Completed

Many operations in the steelmaking process depend on air flow, a prime example being the sintering process for iron ore (prior to charging into the blast furnace), where air is drawn through a bed of the raw material in order to generate heat. The energy required to move the air represents a significant cost in the operations at the Tata Steel plant at Port Talbot.

Swansea University has extensive research expertise in computational fluid dynamics that has been used, for example, to predict air flows around aircraft structures and wind turbines for example. These techniques could be applied to predict air flow in steelmaking and it is thus felt that a collaboration between Tata Steel and Swansea University could lead to significant energy savings and process improvements at the Port Talbot works.

This project will research historical process data from the Sinter Plant with aim of developing a larger multi‐phase research project that could also involve additional collaborations from other HEI partners in the ASTUTE 2020 team.

A vast quantity of data is generated from the process, and the technical work of the project will investigate the application of Big Data analysis technques across the Sinter Plant, with particular enphasis on the fans and electical motors that power the air flow system. The intended outcome of this research will be greater understanding of the inter-reationship of process parameters on the Sinter Plant which should generate positive impacts in terms of reduced energy consumption, reduced C0 2 emissions, and improved plant performance.

Expertise: Computational Engineering Modelling & Manufacturing Systems Engineering

Academic Partner: Swansea University

Location: Neath/Port Talbot

Status: Completed

The project is to investigate the application of virtual reality, augmented reality and advanced data capture within steelmaking process at Port Talbot. The Initial project phase is to commence investigation in the following themes:

• Digitally enhanced steel strip
• 3D visualisation of refractory lined vessels
• Developement of new manufacturing plant using VR, AR and advanced imaging
• Improved techniques for specifying human-machine interaction

Research will be carried out to assess the concept of applying the technology in each theme.

Expertise: Manufacturing Systems Engineering

Academic Partner: Swansea University

Location: Neath/Port Talbot

Status: Completed

Team manufacture a range of pipework assemblies which have formed or machined end fittings and are manipulated/bent to meet the customer requirements. The company are seeking support in better understanding current capability and capacity and ways to identify possible improvements.

This collaborative project will compare the results from Value Stream Mapping and Discrete Event Simulation and optimisation methods.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Carmarthenshire

Status: Completed

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The Smart Container Company Ltd. is the technical solutions company developing the KegTracker, an Internet of Things (IoT) solution that can be added to beer kegs to make them into SMART containers. The KegTracker will collect real time data on volume, location, temperature and movement of each keg it is fitted to.

The Smart Container Company is trying to bridge the gap between brewers, distributors, retail establishments, and consumers by bringing Internet‐of‐Things technology to reduce excess containers and diminish waste in the beer lifecycle. Optimising the supply chain reduces inventory, decreases carbon emissions, increases revenue, and improves customer satisfaction. F&W Insights are developing an IoT device to be retrofitted to beer kegs to provide data to stakeholders to make improvements in supply chain management.

The device will measure and monitor the volume of beer in a keg. Research is required to determine the feasibility of measurement techniques which can be implemented to measure the liquid volume in a keg from an external sensor.

The device will require a self contained power source to provide power to take measurements and commnunicate data to a cloud database system. First iteration product will contain a rechargeable battery system, that will be conventionally recharged.  Research to determine the feasibility of using energy harvesting methods to power/recharge the system will be conducted toward the development of an enhanced version of the product.

Expertise: Manufacturing Systems Engineering

Academic Partner: Swansea University

Location: Cardiff

Status: Completed

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Formally know as F&W Insights Ltd.

Sure Chill is a multi‐award winning cooling technology developed in Wales and deployed in over 49 countries to date in the niche market of medical refrigeration.

Sure Chill’s technology requires novel manufacturing techniques in order to quickly advance the manufacturing processes to enable penetration into high volume production.

Once the high value manufacturing process for high volume has been identified and costed, Sure Chill will investigate automation of the process to lower the cost and be in a position to establish competitiveness in the burgeoning off‐grid/poor‐grid markets.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Cardiff

Status: Completed

Three‐Sixty Aquaculture Ltd. is a land‐based fish farming company based in Swansea. They specialise in recirculating aquaculture systems (RAS). They were the first in the UK (and second in Europe) to operate a commercial tilapia hatchery. Three‐Sixty Aquaculture are currently producing lumpfish which is used to control sea‐lice in Salmon farms and considered to be a ‘green alternative’ to medicine. The company is keen to expand into the farming of high value finfish for local and export markets.

The current research project will use computational fluid dynamics (CFD) methodology to predict and improve the performance of innovative large‐scale fish tanks for the purpose of farming high value finned fish.

The outcome of the project will allow Three‐Sixty Aquaculture to build innovative fish tanks with the highest standards of fish welfare and quality. This will allow Three‐Sixty Aquaculture to expand their operation into farming fish for human consumption which is important for Wales’ food security and economy.

The project impact will be assessed by:

1. Providing Three‐Sixty Aquaculture with fish tank performance data that will enable them to build innovative fish tanks.
2. Swansea University gaining know how in the aquaculture sector through CFD modelling of fish tanks.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Swansea

Status: Completed

Tomoe is a global leader in the design and production of high quality and technically advanced butterfly valves. The valves are supplied to a wide range of industries with stringent demands, e.g. Oil & gas, petrochemical, water treatment etc., operating at high temperatures and pressures. The European headquarters of TOMOE was established in Newport, South Wales in 1986 to develop the business in the UK, Europe, Africa, Middle East and North America.
The ASTUTE East Collaborative R&D project aims to improve the service life of an innovative triple offset butterfly valve. The research will focus on the seal of the valve which is a sophisticated sandwich of metal and graphite. The erosion of the graphite layers, its impact on lubrication and the consequent dimensional changes will all be investigated.

Expertise: Advanced Materials Technology & Computational Engineering Modelling

Academic Partner: Swansea University

Location: Newport

Status: Completed

With the ever growing need to protect workers’ health from the inhalation of contaminants, Toyota Manufacturing UK (TMUK) recognise, that despite continued annual work-place exposure monitoring being consistently below the previous HSE guidance level of 1.0mg/m3 (removed in 2005) and under the Toyota internal limit of 0.5mg/m3, there exists a visible mist within the machining area of the Engine Manufacturing facility. Latest HSE guidance for Mist Control, Inhalation risks (MW01) basically calls for all machining centres to be enclosed where practicable. Where not practicable, extraction should be provided to capture the mist and prevent exposure of workers. After assessing the current condition, it has been recognised that there are gaps which need addressing; consequently, there is currently a programme of retrofitting extraction systems to the processes where these gaps exist.

This project seeks to understand the underlying causes of mist generation within machining cycles. If these can be understood and controlled on the current processes and at the design stages of current and future projects this would eliminate the need for reliance on extraction.

Reducing this reliance would have several major benefits:

• Reduced investment requirements to secure future business.
• Reduced electricity consumption.
• Reduction in waste filters generated from the extraction process.

Expertise: Computational Engineering Modelling and Advanced Materials Technology

Academic Partner: Swansea University

Location: Flintshire

Status: Completed

TWI is a world leader in the development and application of Non-Destructive Testing (NDT) technologies. As part of the IntACom project, TWI have developed a state-of-the-art, rapid, automated compositie inspection system; which utilises a Phased Array Ultrasonic Testing (PAUT) probe. However, an issues in the performance of the device have arisen, that due to a lack of relevant in-house knowledge, TWI have sought ASTUTE 2020’s expertise in investigating.

The project will utilise Computational Engineering Modelling (CEM), specifically CFD, to optimise the couplant delivery of the PAUT to improve the accuracy of the system’s assessment.

Consequently, the device’s accuracy and performance will be improved through knowledge gained. The improvements in performance will result in an increase in saleablity of the product and a beneficial impact for the many composite-based industries that could utilise the optimised inspection system. Resulting in a reduction in inspection/service times and the prevention of parts being replaced unnecessarily.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: University of Wales Trinity Saint David & Swansea University

Location: Neath/Port Talbot

Status: Completed

This collaborative project is concerned with defect analysis and interpretation in large components with complex curvature. TWI has developed an automated inspection system that can acquire 3D data in robotic cells or on-site and display the data for offline analysis. The aim of this project is to produce a new NDE assessment environment that enables the NDT specialist to visualise subsurface defects and internal structure while viewing components, greatly improving the ability to characterise, size and monitor flaws and to plan, effect and monitor repair integrity.

Location: Neath Port Talbot 

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Status: Ongoing

Ultrawave Ltd manufactures ultrasonic cleaning equipment. The company is investigating improved methods of attaching Pt100 thermocouples to stainless steel surfaces and wishes to assess what technologies are available to evaluate the adhesive properties and the ultrasonic performance of the unit, utilising latest non‐destructive characterisation capabilities during in-service operations of the product.

This project will assist the company to investigate and compare the new attachment methodology by using 3D Laser Vibrometry to determine the strain which the structure experiences during excitation at specified frequencies. This project aims to accelerate the testing regime and create confidence in the new solution by eliminating the requirement to run the unit continuously for 10,000 hours. In this way, a typical testing cycle would be reduced to 2500 hours, i.e. a 75% saving in time.

Expertise: Manufacturing Systems Engineering 

Academic Partner: Cardiff University

Location: Cardiff

Status: Ongoing

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UnimaQ is in the process of developing an innovative can trimming process and have part created a functioning prototype. Key enabling technologies and equipment have been identified and implemented. A number of aspects of the machine are still in development. UnimaQ are keen to boost development efforts of the prototype and need to confirm viability, with aspirations of exploitation and a product ready to manufacture for commercial sale.

UnimaQ has developed a laser trimmer that can operate at up to 600 cans/minute which saves about 0.53g/aluminium per can which is equivalent to 220 tonnes/annum/trimmer. The material saving together with less process cutting variation, will also create benefits and efficiencies further down the can manufacturing process, in particular the necking process.

The reduction in scrap of Torch reduces aluminium and steel usage which will have a very positive result in the reduction of the carbon footprint of can manufacturing.

The drive of conversion from plastics to aluminium cans, as a circular and more sustainable packaging choice, the beverage can industry will see strong and continued growth in the next 5‐10 years. These are great conditions and presents excellent opportunities to finalise R&D and commercialize this technology.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Wrexham

Status: Completed

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Ventilo Medical Limited is a Welsh company based in Caldicot and is working on the development of new type of endotracheal tube, the Trauma Tube, that can be applied safely and securely by medical professionals in short term emergency situations such as transferring a patient from point of trauma to the hospital.

ASTUTE East will be collaborating with the Healthcare Technology Centre (HTC) and the Welsh Centre for Printing and Coating (WCPC), both at Swansea University. The objective of the current research project will be charactering the first-generation prototype of the Trauma Tube and provide a baseline for the development of the Trauma Tube. It also demonstrates ASTUTE East’s flexibility in working in close collaboration with other providers to support local SMEs

The outcome of the project will be the development of future Trauma Tube prototypes that will eventually be tested in the field by NHS paramedics.

The impact of the project can be assessed by:
1- Providing Ventilo Medical with 1st generation Trauma Tube characterisation data.
2- Development of an optimised Trauma Tube for manufacturing in Wales.
3- Swansea University gaining experience in a new medical product development, adding to a list of previous successful developments.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Status: Completed

Frontier Medical Ltd manufacture a range of single use plastic moulded Sharps disposal containers. Frontier currently consume 80 90 tonnes of polypropylene each week at a cost in excess of £5million per annum. The hazardous nature of used sharps dictates that the waste containers need to be destroyed through energy recovering incineration.

The potential for using a proportion of recycled materials in Sharps containers is of great interest to Frontier, offering significant commercial impact in terms of both cost saving and reduced environmental impact.

The proposed project will seek to improve the mechanical properties of an identified recycled material and test its suitability as an alternative to the current virgin material used for the sharps container manufacture.

Expertise: Advanced Materials Technology

Academic Partner: Swansea University

Location: Caerphilly

Status: Completed

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Voltcom Group is comprised of three enterprises; a market‐leading overhead line construction and cabling company, a quality & compliance systems provider and a UK‐based fleet management business. By combining these three elements Voltcom Group provide both overhead and underground line installation across the UK from their head office at Llantrisant in Wales.

The project aims to quantify, by simulation and testing, the loading conditions of a deployable protection structure prior to its introduction into the companies operations. The project would provide Voltcom Group with a greater understanding of the operating performance of their newly developed structure. This project will enable the company to offer an alternative system to their customers which should lead to improvement in efficiency.

Expertise: Computational Engineering Modelling

Academic Partner: Cardiff University

Location: Rhondda Cynon Taf

Status: Completed

VortexAir Limited is a start‐up company based in Swansea that is developing a cyclone with an innovative non‐mechanical self‐emptying mechanism. They envisage their cyclone design as a pre‐filter for HVAC equipment.

The objective of the current research project is to predict and improve the performance of the cyclone using multiphase computational fluid dynamics methodology.

The outcome of the project will allow VortexAir assess the suitability of their device as a pre‐filter for the HVAC market

The impact of the project can be assessed by:

1. Providing VortexAir with needed cyclone performance data.
2. Working with VortexAir on assessing the feasibility of cyclones as pre‐filters for HVAC equipment which could lead to the establishment of a manufacturing facility in West Wales and Valleys.
3. Swansea University gaining know how in cyclone’s flow modelling and performance prediction.

Expertise: Computational Engineering Modelling

Academic Partner: Swansea University

Location: Swansea

Status: Completed

Wall Colmonoy is a leading global materials engineering group of companies, that have been based in Pontadawe for 50 years. They are engaged in the precision manufacturing of surfacing and brazing products, castings, coatings and engineered components across multiple high value sectors including:

• Aerospace & Automotive
• Oil & Gas
• Mining & Energy

The company is continually investing in new equipment to expand their product offering, which has led to increased production. In addition, many of the production processes are batched, require significant set-up and are technically challenging. Due to the number and nature of variables associated with the operations, a bespoke sequencing and scheduling solution is required for optimal utilisation of their facilities. Application of mixed integer programming models will provide guidance for more efficient product routing in this multi-process environment.

Expertise: Manufacturing Systems Engineering

Academic Partner: Cardiff University

Location: Swansea

Status: Ongoing

Wall Colmonoy is a leading global materials engineering group of companies, in operation for 80 years with the European Head Quarters based at Pontardawe for the past 50 years.

Wall Colmonoy’s standard and custom range of Colmonoy® and Wallex™ surfacing alloys have outstanding metallurgical and physical properties making them ideally suited to solve engineering problems such as Wear, Corrosion, Erosion and Abrasion. Additionally, Wall Colmonoy is engaged in the manufacturing of brazing products, castings, and engineered components across aerospace, automotive, glass container, oil & gas, mining, energy and other industrial sectors.

This project intends to apply a thorough research‐based approach utilising Computational Fluid Dynamics (CFD), to optimise the production of Alloy Powders by Gas Atomisation. This will allow Wall Colmonoy to move from the current user experience driven approach, to a more robust alternative, supported by a better understanding of the physics of Gas Atomisation Process. It is expected that improved process control will enable the manufacture of the desired Powder Particle Size Distributions with less waste and lower conversion costs.

Expertise: Computational Engineering Modelling & Advanced Materials Technology

Academic Partner: Swansea University

Location: Neath / Port Talbot

Status: Completed

Please click here to read the case study

Founded in 1990, Weartech International Ltd is has a major plant in Port Talbot where they manufacture wear‐resistant, hard‐facing cobalt, nickel, and iron based alloy coatings, consumables and components. Weartech alloys are available in the form of bare rods, stick electrodes and small diameter wires that are manufactured using a continuous casting process, whilst wear‐resistant cast components are made by centrifugal and sand casting methods.

The proposed research project will examine the microscopic structure and mechanical properties of these multi‐component alloys when produced by continuous casting (for line rods), and sand casting and centrifugal casting (for components). These investigations will be supported by computer modelling of the heat and fluid flow during casting and (to include the effects of phase transformations during solidification). In addition, the reduction of the generated reverts from sand casting and machining operations will be addressed through a computational mould design optimisation to avoid costly delays such as those experienced in over manufacturer and re‐cast time. Moreover, the reverts recycling process in casting will be investigated to determine the level beyond which product quality will be affected, allowing for a sustainable manufacturing process that impact minimally on the environment.

Moreover, this collaborative work will focus on the knowledge transfer that enables the company to develop and build a research capacity into wear resistant multicomponent alloys to advance manufacturing knowledge. This will lead into a more efficient manufacturing process and exploit increased market demand for these complex, high‐value alloys.

Expertise: Computational Engineering Modelling & Advanced Materials Technology 

Academic Partner: Swansea University 

Location: Neath/Port Talbot

Status: Completed

Read more about this case study - Microstructure Approach or Computational Approach

The global electric vehicle market is rapidly expanding and is being supported by new technology options. The project looks at optimising these options to create the optimal product which will enable large market share. We foresee a future rationalisation of product specifications so this project is important in order to identify this and also to be ahead.

This project will model, parameterise and simulate the electric vehicle drive system to enable the optimisation of a range of metrics including cost, weight, size, complexity, robustness, and reliability. The aim is to identify the optimal configurations both now and a prediction for the near future. This will include different motors and inverters technologies/topologies as well as expanding the existing optimization tools to overall system performance. The project will consider practical data and also current vehicle designs for calibration.

Identifying the optimal product technology and topology specification would be transformational in respect of benefit versus project cost. The approach of considering and optimising the whole power train is new and will transform the selection of key components. It will also be a key enabler achieving net zero emissions by 2050 at the latest.

Expertise: Computational Engineering Modelling & Manufacturing Systems Engineering

Academic Partner: Swansea University

Location: Powys

Status: Ongoing