Public Funding for Msc.Software Limited

**MariLight2** is aimed at transforming shipbuilding and marine fabrication sectors in the UK, developing and demonstrating **Smart Design** and **Large Scale Additive Manufacturing (LSAM)** technologies that will revolutionise the traditional design and build process. MarilLight, the CMDC2 feasibility project, concluded that topology optimisation could reduce the weight of ship structural components by up to 48% with no impact on performance, and widespread application of these applications could **reduce the the total weight of a typical steel ship by 13%**, with the associated through-life fuel and emission reductions The Malin Group, Caley Ocean Systems, and BAE will showcase its efficacy in a low-risk, pre-production environment through functional component testing. Backed by a consortium of 8 partners and a select Steering Group, the project ensures that outcomes remain pertinent and aligned with industry demands while expediting certification and qualification for a sustainable, data-led, and digitally enabled large-scale manufacturing trajectory. Upon successful completion, **MariLight2** is expected to inject £300M into the UK economy, generate over 100 jobs directly, and create indirect employment opportunities for 5,000 individuals nationwide before 2030\. Anticipated deliverables include 50% production productivity improvements, reliability, and export potential for large-scale manufacturing, and operational cost reductions---such as delay and manual handling---by up to 90%. The innovative thrust of **MariLight2** lies in its comprehensive approach. By integrating circular design principles and leveraging data-rich, automated production, it optimises manufacturing processes. Combined with LSAM methodologies, this results in streamlined, localised, and flexible production pathways. The incorporation of digital product passports delivers a cradle-to-grave traceability approach, enhancing end-of-life strategies and minimising waste. **MariLight2** is set to significantly reduce steel usage in manufacturing, with like-for-like reduction of 31% facilitating potential annual savings of 14 million tonnes in global shipbuilding. It will counterbalance an estimated 12 million tonnes of CO2e, in line with the UK's 2050 net-zero target. The **MariLight2** methodology is expected to curb scrap production by 25%, shrink manufacturing emissions by 37%, and enable 90% of parts to have circular opportunities. Through data traceability, integrated manufacturing pathways, and digital product passports, it aims to augment productivity by 50% and boost reliability by 60%. With key end-users such as Malin, Caley Ocean Systems, and BAE Systems, supported by a diverse consortium of specialists, **MariLight2** meets the industry's call for innovation head-on. It not only aligns with Maritime UK National Priorities, but also the broader global sustainable development agenda, marking it as a **genuinely transformative endeavour**.

Out-of-autoclave Resin-Infused composites provide a key opportunity for the Aerospace industry. Promising high manufacturing rates, lower manufacturing costs, and environmental sustainability through reduced weight of aerostructures. The CoSInC (Composite Smart Industrial Control) project partners have scoped an ambitious and innovative programme of work targeting key bottlenecks and challenges to achieve a robust, repeatable and rate-enabled industrial system. The project will deliver validated simulations for the various stages of manufacture as well as a next-generation digital manufacturing system. This is a collaborative project between Airbus, MSC, Planit Software, the National Composites Centre (NCC), and the Centre For Modelling and Simulation (CFMS).

The use of fibre steering to enhance composite structural performance has been seen as having significant potential for reducing material use and reduction in manufacturing costs. It also has been shown to have capabilities for aero-elastic tailoring. This allows an aircraft wing to bend with a reduced twist. Reducing twist allows the wing to be more efficient over a range of wind speeds. This will have an impact on environmental emissions and improve the economic viability in aerospace structures. This could also be extended into other sectors like automotive and wind energy. Current solutions for fibre steering are automatic tape laying (ATL) and tailored fibre placement (TFP) These have both of limitations. ATL cannot steer with a tight radius and steering causes fibre wrinkling and gaps, compromising the structural performance. TFP is a slow process so cannot deposit material fast enough for anything of a significant size. Also the stitching used compromises the structural performance. iCOMAT have created a new tape laying process, continuous tow shearing (CTS) which promises to rival the speed of ATL but without the wrinkling and gaps. It also can lay around tight radii (100mm). However there is an issue that commercial software does not exist to simplify design, analysis and optimisation of structures using CTS. The project is aiming to develop the prototype CTS head design to a level where it can be introduced to industrial applications. In parallel to this development MSC Software will develop design, analysis and optimisation tools to make it accessible to prospective users. They will also write a tool translating the final design back into fibre paths for the CTS head to follow, completing the "digital thread" in this process. DaptaBlade will develop multi-disciplinary software which will enable coupling of a wing structural model with fluid dynamics analyse to perform aeroelastic tailoring. The project will also create demonstrator structures which will be used to verify the analysis and manufacturing software. These will be structurally tested at TWI.

Forecasts indicate the need for over 30,000 new commercial aircraft by 2034. Securing market success depends on delivering products that meet customer demands and ensuring the long term viability of those engaged in developing and producing them. Innovative product architectures and novel technologies will be needed to achieve the demanding performance targets. The design environment used to develop and evaluate such products will also require transformation to meet the crucial development time and cost reduction ambitions. APROCONE, is a key step towards delivering the next generation aviation products and associated advanced design environment. It will deliver capabilities needed to transform the conceptual definition and evaluation of complex products thus providing the foundation on which to achieve significant improvements in development cost and product performance. The consortium of software specialists, industrial end users/suppliers and academic experts, will collaborate to investigate innovative aircraft wings & turbofan engines concepts, whilst developing and demonstrating the capability of the enhanced Design Environment.

The BAM project researches the use of 3D woven composite material for application to aircraft structures and potentially for use in other sectors in particular the automotive sector. The expected benefits include lower weight structures and reduced manufacturing and assembly costs. The project also considers the design requirements and potential blockers in developing the technology. Suitable candidate structures will be investigated and the associated FE and other predictive software will be developed, delivering an engineering tool set. Manufacturing processes will be assessed and used to manufacture various elements of a typical test pyramid to compare the predictions with the actual performance and to begin thinking about the quality control aspects leading to the route to certification. The overall objectives of the project are to develop the complete process from design to the manufacture of 3D woven composite fabric components thereby enhancing the UK supply chain in the technologies required to deliver more innovative composite structures.

This project is a response to the need to develop new multi-disciplinary design and integration processes to support the conceptual design and assessment of future aircraft configurations. Such developments are essential if designers are to be able to deliver robust product concepts for novel wing and aircraft configurations, making use of new technologies. Airbus and Rolls-Royce, together with a number of specialist industrial and academic technology providers, have joined forces within this project to develop a selection of innovative capabilities to meet the future product needs. By bringing together designers and methods developers, it will be possible to demonstrate and evaluate the benefits gained from adoption of these enhanced capabilities for a range of potential aircraft architectures, making deployment more effective and paving the way for even further capability enhancement in the future. The project started in 2013.

This project is a response to the need to develop new multi-disciplinary design and integration processes to support the conceptual design and assessment of future aircraft configurations. Such developments are essential if designers are to be able to deliver robust product concepts for novel wing and aircraft configurations, making use of new technologies. Airbus and Rolls-Royce, together with a number of specialist industrial and academic technology providers, have joined forces within this project to develop a selection of innovative capabilities to meet the future product needs. By bringing together designers and methods developers, it will be possible to demonstrate and evaluate the benefits gained from adoption of these enhanced capabilities for a range of potential aircraft architectures, making deployment more effective and paving the way for even further capability enhancement in the future. The project will begin in late 2012.

The project focusses on Enviromentally Friendly Transport within the Modern Built Environment. It will deliver a modelling and simulation tool to enhance safety and cost effectiveness of railway transportation through accurate understanding of in-service behaviour, component interaction and degradation. The lack of knowledge of in-service behaviour is a barrier to targetted innovation and is a reason for wasted research effort. The project deliverables will make a significant contribution to the design and manufacture of vehicles and the track system components. It further enhances the functionality and applicability of existing vehicle dynamics models by incorporating an accurate track system model. A much needed contribution will come form a scientifically robust model to assess the criticality of defects within the rail to enable knowledge based management of costly maintenance and rail renewal.