Altair Engineering Limited Public Funding

Project PIVOT - Performance Integrated Vehicle Optimisation Technology

PIVOT will revolutionise the global aluminium casting industry whilst changing the look, performance and environmental impact of future automotive solutions. Casting is the most complex of manufacturing techniques and, as the automotive industry continues to seek solutions for mass reduction (especially for EVs), it has become the most important. PIVOT removes the complexity and time-constraints for lighter, stronger castings by creating a one-stop software that solves casting performance and manufacturing variables whilst allowing the adoption of fully recycled aluminium with 95% lower embedded CO2\. PIVOT represents an extraordinary and transformative step into the future of global casting development and manufacture.

MariLight 2

**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**.

Hyer Power - Hydrogen extended range Powertrain for Special Purpose vehicles including Ambulances, Fire Engines and Road Sweepers

This 3.5 year project which is a collaboration led by ULEMCo Ltd, the specialist hydrogen commercial vehicle company, with partners Technical Services (UK) Ltd for cooling capability, Altair Ltd for vehicle energy system modelling, along with Emergency One for the Fire-Engine solutions and Oxfordshire County Council for the customer input, trialling and dissemination, will develop and test to a full manufacturing-readiness level, a zero-emission hydrogen fuel cell based range extension system for electric drivetrains, which is applied to a series of "world-first" special purpose EV vehicle solutions, namely an Ambulance, a Fire-Engine and an HGV Road-Sweeper. Taking the learning from the prototyped and tested ZERRO Ambulance, displayed at COP26, it creates a tool-kit and "plug & play" set of component modules, utilising the mass-produced Toyota Gen2 fuel cell power-pack and demonstrates its flexibility, accelerated design process, performance and utility to extend range for these applications. Hydrogen is essential for viable zero-emission solutions in these applications, particularly emergency response because of the fast and immediate refuelling that enables the vehicle to be "fit-to-go" and have the full flexibility of range required for the job. Due to packaging constraints and the overall energy demand needed for not only the vehicle drivetrains as well as the onboard equipment, unlike battery only EV, hydrogen solutions are the most cost-productive route to transition to zero-emission fleets. The conventional OEMs are not focussed on developing zero-emission solutions for these applications in the timescales that meet the UK's Net-Zero targets. This project, which enables both supply chain growth in the project partners and the UK specialist vehicle manufacturers, is therefore strategically important in delivering the UK's obligations for GHG reduction by 2050, and it's corresponding clean growth opportunity.

Project Gamma

The project will investigate key automotive battery technologies and concepts that will enhance the attributes of future Jaguar Land Rover (JLR) electrified vehicles from 2026\. The project will focus on an integrated structural battery pack and wireless communicating battery cells to enable increased efficiency, reliability and sustainability. The project will support growth of UK manufacturers of automotive battery components and products.

Marine Vessel Lightweighting (MariLight)

The marine transport industry contributes towards 940m tonnes of CO2 emission annually(2.5% of the global greenhouse emissions). The International Maritime Organisation (IMO) is committed to reducing emissions from international shipping and is working to phase them out. Its initial strategy identifies technological innovation as integral to achieving the overall ambition, whilst introducing rules requiring ships to be designed and built in an energy-efficient fashion, measured by the [Energy Efficiency Design Index][0] (EEDI). In the UK there is considerable emphasis on reducing emissions to reach greener maritime transport solutions, with the stated target of decarbonising all sectors to achieve 'net zero' by 2050\. This will be accomplished by progress in many aspects of design and operation, but the starting point will be **minimising ship weight and power demand**, **improving underlying vessel efficiency** so that new propulsion technologies will have the most significant impact. From a practical perspective, it is critical to address inefficiencies in existing design and manufacturing processes that prevent industry growth, making best use of Industry 4.0 developments to increase process automation, improve quality, reduce manual activity, and enhance working conditions. The MariLight project will achieve this, providing the marine industry with initial steps to move from conventional, manual fabrication that requires labour-intensive work, to an automated and flexible manufacturing route, with potential to deliver complex designs through **topology optimisation design and Large-scale Additive Manufacturing (LSAM).** Expected benefits include: \***13% vessel weight saving,** \***global fleet savings of 7.7m tonnes of steel,** \***90% manufacturing lead time reduction,** \***60% production fuel/energy savings,** \***20% reduction in production time.** This feasibility study will demonstrate a transformative design and manufacturing process route that reduces current shipbuilding manufacturing environmental impact by **60%, providing \>10% emission savings throughout a standard 30-year service life.** Led by **Malin Group**, MariLight will generate a robust Business Case, detailing features such as lightweighting, CO2 reduction, and cost benefits to inform not only the marine industry, but also other industry sectors. This will be achieved by introducing topology-optimised design and regulatory frameworks to produce **lighter shipbuilding components** utilising LSAM techniques. The extensive expertise from the consortium also composed of **Altair Engineering, BAE Systems, Lloyd's Register, and the National Manufacturing Institute Scotland (NMIS)**, the project will permit achieving reliable outcomes that can be exploited by different markets (e.g., automotive, Oil & Gas), providing the UK with opportunities to be more competitive and diversified, whilst creating jobs in highly skilled areas. [0]: https://www.imo.org/en/OurWork/Environment/Pages/Technical-and-Operational-Measures.aspx

AMPERE - Additive Manufacturing for Power-dense Electric motor Enhancements

This project aims to utilise Additive Manufacturing (AM) to address the key issues with current electric motor design to deliver step changes in power density. The consortium will build upon the existing class-leading motor architectures from Equipmake and utilise targeted cooling of rotor and stator components. HiETA bring their expertise in thermal management and additive manufacturing, with Altair developing their multi-disciplinary optimisation workflows. The consortium will develop and run a prototype system on a bench test station within Equipmake test facilities.

POSTIE: Physical Optimisation of Structural Topology for Integrating Engines

POSTIE will develop a weight-optimised structural solution for the Rolls-Royce UltraFanTMgeared aero engine and additionally investigate the potential added benefits of topology optimisation.POSTIE is led by Rolls-Royce plc. in partnership with Altair, and will strengthen the UK Fast Make supply chain. The project duration is three years andis due to be completed at the end of Q2 2020.