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104,332
2020-11-01 to 2023-10-31
Study
Additive Manufacturing (AM) also known as 3D printing is a process where objects are produced by adding and depositing material in layers. AM offers significant advantages over traditional manufacturing namely design freedom,lead time reduction and lightweighting resulting to increased performance, cost reduction and new business models-digital inventories. Most AM systems comprise of a motion system, heat source and feedstock(raw material). Wire Arc Additive Manufacturing (WAAM) is the combining of a robotic manipulator, using an electric arc as the heat source and wire as the feedstock. WAAM also offers the distinct advantage of being able to produce near-net shape designs in a large scale \\\>1m long. Currently WAAM is focused on high value parts weighing a few tens of kg made out materials such as titanium for the aerospace sector. Current build rates for WAAM are quite low at 2-3 kg/hr. Other industry sectors such as mining, energy and construction use lower value materials e.g. steels and are showing interest in WAAM application. In these industries the production processes are casting, forging combined with machining and/or fabrication reliant on manual operations. Parts often weigh several hundred kgs or even tons, with lengthy production time frames. To make a viable business case for WAAM in these industries, the deposition rate needs to increase dramatically to \\\>15kg/hr for steel, whilst maintaining precision and low recurring costs. In this project a new High Productivity Wire Arc Additive Manufacturing Process (HPWAAM) will be developed to manufacture large scale parts and structures used in engineering and construction industries with high quality and deposition rate of up to 15 kg/hr. To help achieve this new high-quality shaped filler wires (Wintwire-SME) and overall heat control using cryogenic cooling (BOC) will also be developed. **Aim** Demonstrate a new High Productivity Wire Arc Additive Manufacturing process for manufacturing large components and structures for mining, oil&gas and construction industries. **Objectives** Industrialise the HPWAAM process for large-scale engineering components,featuring full thermal control and variable resolution (CU, WAAM3D-SME). Upgrade existing planning and control software to commercial grade enabling implementation of HPWAAM in an industrial environment. Demonstrate the capabilities of HPWAAM for production of \\\>100kg steel components for mining and construction applications. Led by Weir Group this challenging project consists of a consortium covering all aspects necessary for industrial implementation of HPWAAM; process technology development (CU, BOC), supply chain (WAAM3D, Wintwire), end users (Weir, Fosters+Partners) and steel fabrication supplier (Steelo-SME).
0
2019-06-01 to 2020-05-31
Feasibility Studies
"**Overview** This project will enable a proprietary blend of human and autonomous drone control. The aim of the project is to build a proof of concept of a service that has the capacity to match or exceed what's currently possible with a drone using conventional 'visual line of sight' rules - with significant cost, flexibility and scale advantages. **Team** Lead: BeTomorrow (BTO). Our senior team has over 100 years of combined experience across engineering, sales and marketing - at Apple, ARUP, CERN, Cognizant (Zone Digital), Google, Landrover BAR, McLaren Automotive, McLaren Racing and Oracle Team USA. Partners: Skanska, Foster + Partners, NATS, Vodafone and SLAMcore."
69,015
2017-04-01 to 2018-03-31
Collaborative R&D
Defects in construction work cost billions globally and >£9bn / year in Great Britain alone. Spotting defects quickly and reliably is key to avoiding or reducing these costs. Current surveying/monitoring techniques are labour-intensive, slow and prone to repeating errors. No solution currently exists to autonomously survey the inside of a construction project, where most problems are hidden (even if drones can do so externally). In this project we propose developing an autonomous drone-based solution that can quickly, cost-effectively and reliably verify accuracy of a recently built internal environment with respect to its proposed design, in order to identify construction defects. Such a service will offer big benefits to the construction industry and building contractors in particular, because, for a relatively small investment, it will help lower overall project costs and risk, while also helping increase quality, client confidence and ultimately sales.
0
2017-03-01 to 2019-03-31
Collaborative R&D
Concrete is widely used in construction due to its ability to provide structural capacity andfunction cost effectively and at scale. However, its role in construction does not lend itself tocreativity in design. High-end clients typically demand state-of-the-art designs, presenting achallenge in a sector where every building is essentially different to the last. The CAMBER project will seek to develop an innovative 3D concrete printing (3DCP) platformthat meets these demands. 3DCP has the potential to deliver more creative designs whilst stillmaintaining building function cost effectively. However, there are challenges that need to beovercome in terms of materials supply to the printing nozzle, providing support material for theconcrete prior to setting to produce complex geometries and overhangs, finishing afterplacement to provide a suitable surface and materials formulation. Work is also needed to linkthe 3DCP to building information modeling capabilities. Additionally a 3DCP capability needsto be mobile such that it can be readily set up and used on a construction site (or in temporary,near-site factory) in order to optimize productivity in line with recent construction processinnovation.Building on recent R&D work and IP developed within the consortium CAMBER will addressthese barriers and opportunities. Led by Skanska to ensure that user needs remain a focus andto provide a route to market, it brings together a strong, supply chain-orientated consortiumfrom construction (Skanska, Tarmac, Fosters + Partners, BRE), manufacturing automation(ABB, MTC, Loughborough University) and an SME digital solutions provider (HAL). It builds onprevious R&D work (and IP) by project partners (including innovation in the application of BIMto product design, as well as materials, process and finishing). It will develop a mobile additivemanufacturing platform (and associated supply and processing capabilities) for the costeffective,mainstream 3D printing of a wide range of large concrete components (includingcomplex geometries), such as façade units, wall panels, partitions, street furniture etc. inprecast concrete factories or via the mobile platform in a near/onsite flying factory. The initialfocus will be on meeting the requirements for 'high-end' markets. However, successfulimplementation and subsequent economies of scale will mean that the approach will be costeffective in more mainstream construction markets. The platform will integrate recent digitalconstruction sector innovations -- especially Building Information Modelling (BIM).