ASCEND is an industry led, cross-sector consortium brought together by GKN Aerospace, focussed on developing & accelerating UK composites capability to meet the requirement of single aisle, business jets & future mobility markets. ASCEND will develop the UK value chain in readiness for a step-change in use of lightweight structures, at high-rates.
ASCEND brings new entrants, established small, high-growth & Tier-1 partners together to collaborate on delivering flexible automated capability. Connecting best in-class of talent, experience, & market access in one programme. ASCEND delivers UK capability for advanced, lightweight structures to meet demand in electric & hybrid propulsion aerospace structures.
A consortium led by McLaren Automotive, the pioneering British creator of luxury sportscars and supercars, along with partners including a world-class cell manufacturer, a technology company at the forefront of materials innovation and a leading university, aims to accelerate the development of electrified powertrains to help reduce vehicle mass, minimise emissions, and match traditional powertrain usability characteristics. The consortium identifies that current electric technology is not sufficiently mature for the demands of high performance cars due to high weight, range limitations and battery management challenges. Through the development of new materials for cells and a modular designed battery, the consortium aims at delivering advances needed to achieve improved levels of functionality and performance, which may one day benefit volume car buyers.
A consortium, led by an automotive OEM, with partners including a composites specialist and a high value manufacturing catapult centre, aim to develop technologies that will significantly reduce the cost of utilising advanced composite materials in automotive applications. Through a combination of reduced material wastage and automated pre-form manufacture, these technologies will have a significant impact on the cost of resin transfer moulded composite components. Not only will they be of benefit to the automotive industry, but also to other industrial sectors such as wind energy, sporting goods and aerospace.
The aim of the AMALGAM project is to develop and demonstrate a revolutionary approach to the design and
manufacture of compound boosting systems, leading to improved engine efficiency and lower CO2 emissions.
The new approach combines the latest hybrid laser cladding and 5-axis machining AM approach with parts
produced by powder bed fusion AM and conventional manufacturing in a single “join as you make” operation.
This will provide a cost effective, efficient and flexible method of producing high performance automotive
parts, using the optimum combination of processes. The AMALGAM approach enables novel part design and
material combinations to be used which will have a dramatic impact on performance. The new approach is not
restricted to boosting systems but can be used in a wide range applications in motorsport, low volume and
mainstream vehicles, as well as the wider high volume manufacturing sector.
The RHIFALS project involves three high-tech UK-based companies working in a consortium
along with the University of Warwick to improve large scale 3D printing, capable of printing
parts several metres in size.
The project focusses on improving two main areas of the digital workflow involved in operating
the equipment --thereby improving the efficiency of the system, reducing both process time
and cost. Additionally, the project will focus on the procedures necessary for mass-production
and will demonstrate the suitability of such a manufacturing approach for the future direct
production of components for automotive manufacturing.
The successful delivery of the project will help put the UK at the forefront of industrial 3D
printing technology development as well as contribute significantly to the continued strength
of its network of leading Automotive OEMs.
Increasing the power-density of batteries is vital to accelerate the widespread adoption of electric vehicles and to reduce their weight. This project aims to develop a High Power Lithium Storage Device (HP-LiSD), with a modular design and at least 5kW/kg, compared to 1-2 kW/kg for the best hybrid lithium ion batteries today. BMW Motorsport Limited will collaborate with McLaren in research, design and development of the battery system for high performance hybrid and full electric vehicle applications. Electrochemistry know-how will come from the University of Warwick with battery cooling and module expertise coming from SME Delta Motorsport Limited. The intention would be for these batteries to power both McLaren and BMW Group cars in the future.
The TACDAM project will perform targeted Additive Manufacturing (AM) pre- and post-processvalue chain technology developments, develop an adaptive quality assurance model, introduceparametric design as a key process variable and demonstrate the capability to deliver cost andquality outcomes at Manufacturing Readiness Level 6 to the automotive industry.
McLaren Automotive, Ricardo, Grainger and Worrall, Lentus Composites, the University of Bath and a major European OEM have been awarded an APC grant to develop a high specific power, modular combustion system and associated engine technologies for application in future vehicle programmes.
The APC grant will support the development of a completely new generation of technically advanced engines offering significantly improved CO2 figures for high performance vehicles.
The grant will also improve the UK’s development and production capabilities for low CO2 ICE technology.
The European OEM will transfer skills and development experience of engine systems to McLaren Automotive; Ricardo will extend its capabilities in the same areas; Grainger and Worrall will deliver complex, lightweight casting technology; Lentus Composites will seek grow from an SME status to a full automotive tier 1 supplier; and the University of Bath will advance capabilities in ICE system efficiency R&D.
hofer powertrain UK, Warwick Manufacturing Group at the University of Warwick, YASA Motors and a leading Automotive OEM have been awarded an APC grant to develop a premium, high performance driveline solution for application in future vehicle programmes.
The APC grant will support the development of a completely new generation of technically advanced driveline modules offering significantly improved CO2 figures for high performance vehicles.
It will also improve the UK’s development and production capability for advanced driveline solutions through the transfer of skills and research experience of transmission systems from hofer Germany to hofer UK as well as the development and productionisation of advanced axial flux e-motors by YASA Motors from their factory in Oxfordshire.
With the ever more stringent requirements on improved fuel efficiency and CO2 emission reduction for road vehicles, a key enabling technology is the use of advanced composite materials to significantly reduce the mass of vehicles on the road. Life cycle analysis has shown that approximately 15% of total CO2 emissions results from material and parts production, assembly and disposal. The remaining 85% of the CO2 is emitted during operation and driving. The lighter the vehicle is, the less fuel is burnt and the lower are the CO2 emissions. A 10% reduction in vehicle mass improves fuel consumption by 7%, and every litre of fuel saved reduces CO2 emissions by 2.6kg. Advanced carbon fibre composite materials have higher strength to weight ratios, better chemical and heat resistance and greater design flexibility when compared to conventional automotive construction materials. A consortium, led by an automotive OEM, with partners including a material supplier, high value manufacturing catapult centres and an academic institution, aim to develop technologies that will significantly reduce the cost of utilising these advanced materials in vehicle structures, a traditional barrier to date. Through a combination of reduced material wastage and automated pre-form manufacture, these technologies will have a significant impact on the cost of resin transfer moulded composite components. Not only will they be of benefit to the automotive industry, but also to other industrial sectors such as wind energy, sporting goods and aerospace.
The electrification of road transport enables lower carbon emissions. However, conventional motors are not optimised for both weight and cost. This project aims to develop a new variation of switched reluctance machine that has the potential to meet both requirements. The power electronics required will be co-developed to ensure an integrated cost effective package. This project has the potential to make a significant impact on the cost reduction of electrified vehicles.
The objective of this 2.5 yr long project is to demonstrate the clear competitive advantages of the use of Additive Layer Manufacturing (sometimes known as 3D Printing) in the manufacture of production metal and polyamide components. The project will demonstrate that ALM is now a reliable and potent production technology which can be included in the gamut of standard manufacturing techniques. This will be done by addressing three key issues, those of ALM component error correction, the automatic finishing of ALM components to acceptable standards, and the generation of ALM Production Part Acceptance Procedures for the industries involved, as well as process control plans and design guides for parts. The project will be led by CRDM Ltd, with McLaren Automotive, Delcam, Selex, Ultra Electronics and Flitetec as its partners. This strong consortium will ensure that the validated ALM techniques will be robust, exploitable and disseminated widely.