Public Funding for Moog Controls Limited

The FETCH project is led by Moog together with the partners Bath University, Cranfield University, sensor specialists Druck/Curtiss Wright and bearing specialist Carter Manufacturing. The project will develop and demonstrate a fuel control system for aircraft hydrogen gas turbines together with non-fueldraulic geometry electro mechanical actuation systems.

Project CONVERGENCE delivers a structured approach to implementing a 'digital thread'; incorporating Industry 4.0 innovative technologies such as future factory design modelling and optimisation, smart automation and flow-line enhancement. The industry led project is supported by key suppliers and research organisation capabilities. The increased capacity gained by the projected efficiency improvements will secure future high value work from the UK aerospace sector and enable the in-load of additional non-UK manufactured products. The increased capabilities and established technology innovations will be disseminated to both the project partners and wider industry through a Smart Factory Learning Centre and a SME Digital Handbook.

Electrical machines such as electric motors currently have limitations caused by the failure of critical components at elevated temperatures. Research at the University of Nottingham has focused on developing a deep understanding of the primary cause of this limitation - the degradation of the insulation surrounding the copper coil within the motor. This insulation is there to protect the numerous windings that constitute the active part of the motor from touching each other and causing partial discharge and short circuits. As the insulation degrades, the functionality of the insulation is compromised and the motor eventually fails. This project aims to take the results from the work done at Nottingham and use this to improve the temperature capability of electrical machines produced by Moog. Improving this capability will mean that motors will be able to operate in areas that they currently cannot due to the high temperature surrounding it. If the insulation and the motor is able to operate in a higher temperature environment, the need to cool it is removed. Consequently, in the case of aircraft, where weight is king, heavy and expensive cooling systems that are currently required to cool the motors will no longer be needed, saving weight on the aircraft and therefore, achieving reductions in emissions as the same propulsive energy is pulling less weight. The benefits derived from this project will drive the business case for locating new investment in this technology by Moog to commercially produce products based on this technology in the UK.

It is estimated that 150,000 people per year will suffer a below knee amputation and this is increasing due to increases in the prevalence of diabetes and related vascular disease. The loss of mobility that comes from loss of limb leads to decreased social and economic participation as well as further health issues. Current prosthetic feet do not adequately address lost muscle function leading to: reduced mobility; falls and fractures; and damage to the spine and remaining leg due to asymmetric and high loading. This project develops a robotic prosthetic foot to emulate lost muscles by integrating technologies including additive manufacturing, hydraulic actuation, advanced sensing and microprocessor control.

Vehicle efficiency, regardless of the powertrain type, can be increased through several strategies, including reducing weight, aerodynamic drag, reduction in rolling resistance and powertrain efficiency. Out of all, weight reduction is considered to have the greatest potential to increase vehicle efficiency and thus to reduce the CO2 emissions. The objective of the FLAC project is to progressively develop and demonstrate a portfolio lightweight automotive components with increased efficiency and functionality utilising an integrated SLM design methodology, a novel class of lattices, new aluminium alloys for SLM and demonstrate the viability of selective laser melting as a manufacturing route.

NEMICA is a UK collaborative research and development project between Microsemi, Moog and the Universities of Bristol and Southampton. The project aims to develop reprogrammable memories and gate arrays based on Nano-Relay technology that are capable of withstanding long term exposure to 225oC and/or 100Mrads. The primarily target application will be avionic actuator systems but the technology has markets in space, transportation and down hole drilling.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

The uptake of additive manufacturing processes in higher volume production is significantly limited by the lack of an integrated solution for the manufacture of precision components which require further finishing processes. Project FALCON (Finishing of Additive Layer Components On a Novel platform) aims to deliver a disruptive and logically integrated hybrid manufacturing solution for the finishing of near-net shaped complex precision components which are typically produced by (but not limited to) additive layer manufacturing. This aim will be realised by combining and integrating a range of subtractive processes such as CNC machining with finishing processes and inspection to ensure process control and part validation. FALCON will be based on utilising a novel dematerialised energy efficient parallel kinematic machine platform (PKM) to enable realisation of the hybrid solution. The project will provide a unique solution offering a major breakthrough in floor to floor times, component cost and routing simplicity for a wide range of components applicable across many industrial sectors.

A consortium including Moog Controls Ltd, Renishaw Plc and the University of Bath has been funded to investigate new integrated motion control devices. The consortium are conducting research and development in the fields of selective laser melting, piezoelectric actuation and non-contact absolute digital position sensing. The technical aims of this work are to radically change the shape, architecture and performance of motion control devices for aerospace and industrial markets.. The non-technical aims of this work are to retain high quality engineering jobs in the UK, reduce material waste, and reduce weight of aerospace components.