The Ishisuki project sees HiETA team up with NPL to develop understanding in the mechanical measurement methods for complex additively manufactured thermal management products where standard test methods are not appropriate. The project will address methods of quality control and establishing process variation limits which will enable HiETA to reach higher technology readiness levels for products developed for the motorsport, aerospace and energy sectors. These developments will provide a significant boost to HiETA's competitiveness within these markets.

Development and qualification of disruptive large-scale laser powder-bed fusion machines (LPBF) to enable agile production of lightweight, high-performance aerospace components of up to 0.5m in scale, with a roadmap towards 1m. The machines will reduce component costs by delivering unprecedented build rates by delivering multiple laser beams, by full build changeover automation and powder removal, by providing a new level of process consistency and control, and by using more cost-effective powder feedstock. This will enable smaller, lighter components, contributing towards net zero aviation, through exploitation of superior material properties and through innovative design for AM.

Project ALLOWS is a feasibility study into the Advanced Liquid Cooling of Power Electronics in relation to next generation Electric Vehicle Powertrains. HiETA Technologies Ltd, and the Compound Semi-conductor Applications Catapult (CSAC) are leaders within their fields of the development and production of Metal Additive Manufacture (MAM) components for thermal management and light-weighting, and compound semi-conductor technologies respectively. They have identified the building blocks for highly integrated cooling of the power electronics, mainly inverters, needed for e-powertrains in the electric vehicle (EV) market. Mass deployment of EVs requires smaller, lighter, higher speed, more efficient and more power-dense e-powertrains, which in turn require innovative cooling solutions for all components, particularly the inverters. CSAC and HiETA are combining to develop more efficient cooling systems that reduce or even eliminate some of the thermal barriers between electronic components and coolant, while making more efficient use of the coolant available, to meet the packaging and temperature control requirements of the e-motor. After assessing state-of-the-art Automotive Power Electronics Modules and their technical, commercial and environmental challenges and opportunities, CSAC will acquire a current power electronics unit and test its performance to provide a benchmark for subsequent improvement. CSAC & HiETA will then assess the feasibility of innovative cooling methods, from optimisation of current packages, to complete redesign of chipset modules and the use of HiETA's most innovative single or 2-phase heat exchange surfaces and geometries. After detailed analysis of thermally optimised concepts, a selection of technology demonstrator units will be manufactured at HiETA's state-of-the-art MAM facility in Bristol, and then performance tested against current technology at CASC's test and development centre in Newport. An investigation into commercialisation and volume production within a complex supply chain will be investigated. Successfully completing Project ALLOWS will give the foundation for the realisation and improvement of next generation Power Electronics within EV. The primary focus in enabling chipset modules to become more power dense, efficient and more integrated will ensure the evolution of next generation electric motor technology in the UK. In particular, it will enable the development of e-motors with power densities of over 20 kWe/kg compared with the state-of-the-art 12%, resulting in a decrease in typical EV mass of ~3% and an increase in range of up to 10%. Not only will this allow the development of next generation EV's but it will directly create design, manufacturing and supply chain opportunities in a rapidly increasing global market.

By enabling Additive Manufacturing (AM) parts in highly regulated sectors, DAEDALUS will help make the UK the place to manufacture the products that will drive the future of the world, addressing the UK Grand Challenges \[1\] (future electric aircraft for urban mobility and clean growth, and medical devices for ageing society).The adoption of AM in these sectors (e.g. aerospace, space, oil & gas and medical) is hindered by part quality issues, process repeatability and reliability, traceability, scalability and limited availability of AM standards. These challenges are inherently linked to the ability to generate (sampling); capture (in-process monitoring); process (signal processing); store (data architectures); structure (data schemas and standards); manage (traceability provision); analyse (data correlation and insights) and share (manual data, different platforms) highly complex data across the AM process chain (i.e. powder management, build process and post-processing) and the supply chain. Therefore, digital manufacturing is a key enabler and solution, which is the core objective of DAEDALUS.DAEDALUS is aiming at developing a novel solution, with a combination of IDTs (AM, IIoT/Connectivity, AI/analytics) to build the digital thread and analytics solutions to enable AM adoption and scale-up and accelerate qualification of AM parts in highly regulated sectors.**AM Digital Thread:** Development of single, traceable, digital thread and its flexible integration of facility/production management systems to streamline, standardise and digitalise best practices across the AM supply chain focusing on powder management, process and post-process optimisation.**AM Intelligence:** Development of AI-enabled solutions for material and process control and stability through the utilisation of materials, sensor and in-process monitoring data.This solution will be demonstrated for three steps of the AM process chain individually (powder management, build process, machining) in a combination of pre-production and industrial environments. The final demonstrator will be a digitally integrated AM supply chain: a secure collaborative, intelligent and independent platform whereby reliable AM raw material and product traceability data can be shared securely between AM supply chain partners.The final solution is intended to generate game-changing improvements in operational efficiency, including yield, material cost and lead-times. The solution will also make a radical improvement in qualification and certification times for the AM supply chain. As a result, significant improvements in time to market are also expected.DAEDALUS will influence the future of manufacturing, by anchoring light-weighting, electrification, customised medical implants and devices in the UK supply chain and help invigorating the associated digital tech ecosystem.

See attached signed ' Project Change Request #4 - Scope Clarification ' letter from Rolls-Royce

Awaiting Public Project Summary

"Intelligent Fault Detection for Additive manufacturing (IFDAM) is a ground-breaking project to embed machine learning and AI into the laser powder bed fusion (LPBF) process. HiETA Technologies Ltd is a market leader in using LPBF process to produce highly efficient and lightweight thermal management solutions for motorsport, automotive, aerospace and energy applications.Metal AM technologies are seeing a substantial growth and currently rely heavily on post-process inspection methods to determine part build quality. This is costly and time consuming. Failed parts are not identified until significant value has been added to the component as it travels through the production value chain. For example, a defect during the AM build process may not be identified until it has been leak tested. By this point up to 70% additional value has been built into the component. The cost savings which can be achieved through the IFFAM project are considerable through waste reduction in the manufacturing process as HiETA will be able to stop adding value to defective parts.In-process monitoring technology has recently become available but is yet not proving its value to be implemented in the AM process chain. The current challenges are: 1\. Generation of big streams of data at high frequency 2\. Storage, collection and analysis of data, i.e. centralised servers for data storage, absence of data mining and predictive analysis 3\. Absence of control strategies i.e. reactive response (via alerts) rather than corrective response once the defect has been detected.The IFDAM addresses these challenges in the following ways:1\. Adaptive data management i.e. selection of most useful data and development of data dimensionality reduction techniques 2\. Enable mining the relationships between part design, materials, and production processes to predict performance and validate those results against physical test results 3\. Development and validation of corrective/feedback control actions using deep learning algorithms for automated fault detection and correction to reduce the number of post-build inspection and costly certification experiments for the aerospace and energy sectors. With the support of STFC and NPL, IFDAM will drastically improve the in-process inspection methodologies to allow for in-line quality evaluation of components. Ultimately this will allow HiETA to bottom out root causes of part defects, designing them out for future components massively reducing reject levels and allowing HiETA to use AM to compete on price and quality with more traditional manufacturing processes."

"OCTOPUS builds on the success of previous Innovate UK project APEX. **Advanced Electric Motors Research** and **The Thinking Pod innovations** will focus optimising the integrated motor and power electronics 'drive' technology and further integrating with a new transmission and thermal management system to deliver the ultimate single unit e-axle solution designed specifically to meet **Bentley Motors** performance specifications. OCTOPUS will use the world class synchrotron and high performance computing systems available from the **Science & Technology Facilities Council** to build new multi-physics modelling solutions and expertise of the **University of Nottingham** to build power electronics modelling solutions and validate them with test data generated by 'looking through' the motor while its running at its maximum operating speed of 30,000rpm. The prototype e-axle, manufactured by **Advanced Electric Machines** at their expanded manufacturing facility in Washington Tyne & Wear, will be tested to OEM Design Verification (DV) standards using the latest testing solutions and test specifications developed using both **University of Bath** and Bentley Motors vast powertrain testing experience, ensuring that it comes out of the project ready to be considered for a vehicle programme. Looking beyond the next generation, OCTOPUS will develop a suite of technologies which target the 2035 Auto Council performance targets by integrating the latest thinking in Additive Manufacturing and nano-material technologies. **Hieta Technologies** will deliver beyond state of the art thermal management and lighweighting solutions in both the motor and transmission while **Talga Resources** UK will develop materials for high performance motor windings delivering an aluminium based solution which will aim to out perform copper. By working on these technologies alongside the core e-axle design, OCTOPUS will aim to accelerate and focus their development with a view to incorporating successful elements into the testing and prototype units, laying the foundations for future design verification programmes. At the end of OCTOPUS the project team will deliver: * **An e-axle prototype** incorporating the latest magnet free motor, wide band gap power electronics and lightweight transmission systems, tested to OEM DV standards using a new test protocol proven on next generation test facilities * **A new multi-physics simulation modelling toolkit** incorporating electromagnetic, mechanical, thermal and NVH solvers operating simultaneously, validated by a never before demonstrated x-ray analysis technique * **Next generation lightweight high performance component systems**, integrating the latest material and manufacturing techniques and tested at component, sub-system and system level and with an integration route into future e-axle designs"

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.

Commercial vehicles contribute to 25% of all transport CO2 emissions in the EU, but to date have not been subject to CO2 emissions regulations. Commercial vehicle CO2 regulations are expected within the next 5 years. Additionally, air quality in cities is increasingly has become a major issue, leading to many cities announcing stricter emissions legislation in poor air quality areas. These developments will lead to an increasing requirement for zero emission capability for commercial vehicles. All medium and heavy commercial vehicles require a compressed air supply for brake and suspension operation. Conventionally the compressor is engine driven, however zero emission running requires that the compressor be electrically driven. Current solutions to this need are inefficient, heavy and expensive. Equipmake, Hieta, Bladon, and University of Bath will under this project collaboratively develop a novel high speed twin turbine compressor utilising state of the art developments in the fields of turbomachinery and power electronics producing a more efficient, significantly lighter and lower cost compressor. The product will act as an enabler to accelerate the adoption of zero emission commercial vehicles.

"This project will create an innovative approach to additive manufacturing of fully functional metal components, providing both large scale and low cost to the user. The approach is based 3D printing of parts from a liquid which contains a very high metal content in an organic binder which is photo-curable under visible light. This forms a green body which is then fired to remove the organic content and sintered to full density. This combines the advantages of processes such as metal injection moulding (e.g. excellent resolution of true net-shape parts and removing the need for post-processing to achieve a suitable surface finish for engineering parts) with the flexibility of mass customisation achievable in additive manufacturing, since mould tooling is not required. Over the last 3 years, Photocentric, an established UK manufacturer of photo-curable resins, has developed a new type of 3D printing process using light in the visible range of the spectrum to cure the polymer instead of UV. This enables normal LCD screens as found in iPads and televisions to be used as the image creation device in the 3D printer, reducing costs by an order of magnitude in comparison to laser-based systems. A range of innovative printers has been successfully brought to market for creating plastic objects at lower costs and in larger formats than previously possible, taking advantage of the wide array of high resolution screens available. Now, with the aid of InnovateUK, this consortium will extend the technology to develop a process to deliver custom parts for all industrial sectors in many different metals. LPW, a leading provider of metal powders and TWI, one of Europe's largest research and technology organisations, will work with Photocentric to develop the process. The consortium will develop the ink, the metal 3D printer and the printing process. Industrial direction and process validation will be achieved through the involvement of Hieta, one of the UK's leading exponents of additive manufacturing. The process will enable rapid production of low cost custom metal parts in many different metals supplying them to a variety of industries- all made without tooling direct from a digital file."

Additive Manufacturing (AM) is a highly disruptive and rapidly developing manufacturing technology with the potential to revolutionise the design, manufacturing and supply of parts, particularly within key high value manufacturing sectors. AM affords design freedom that can result in highly complex geometries. The benefits are enhanced functionality, significant mass savings and (potentially) reduced components cost. Although an inherent advantage, such geometric complexity provides a significant challenge for the inspection of AM parts. X-ray Computed Tomography (XCT) generates a 3D image of the object, thus allowing detection of entrapped powder and voids, measurement of deviation of all surfaces and, potentially, extraction of surface topography. XCT can be used: During the product and process development to understand failures; the information obtained can be used to reduce the likelihood of build failure at each design iteration. Post-build to verify the quality of the product. XCT is the only viable method for non-destructive imaging (US Air Force Research Labs, 2014) and measurement of metallic products with surfaces that are inaccessible to conventional inspection technologies e.g. optical scanning and tactile probing. However, the capital costs are high and so increase the cost of AM product development, part qualification and, in production, of post-build inspection. 3in1XCT will develop the world's first system (hardware and software) to integrate advanced NDT, dimensional inspection and high-fidelity surface topography extraction for complete postbuild inspection. The platform will eliminate the need for other hardware (2D X-ray, optical scanners, surface profilometers, cut-up etc.) and so reduce the inspection cost per part. Within the project, the data obtained by the 3in1XCT platform will be exploited to provide feedback to digital tools for design and process modelling. This will be the first implementation of direct feedback (real-time within the product development loop) from XCT to design, with the expectation that this could halve the number of design-build iterations during the AM product development cycle. Fully automated workflows for both 3-in-1 inspection and for feedback to the design tools will be developed, eliminating the effort needed from experts in 3D image processing. The system will be tested using complex, real world examples provided by the end-users in the project. The project has representation from automotive, aerospace, space, defence and power generation- all high value, highly regulated sectors for which the high costs of product qualification and inspection creates a barrier to the adoption of AM technology.

Awaiting Public Project Summary

This project investigates the technical feasibility of creating a combined steam and radial turbine expander and integrated electric machine to enable step-change emissions reductions and efficiency improvements from waste heat recovery systems. The consortium will carry out conceptual design work, manufacture a prototype and carry out some limited bench testing of the turbine and e-machine in order to assess its technical feasibility, and make recommendations for future development as well as an assessment of commercial feasibility.

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.

ENTRANCE will develop , at feasibility level, an integrated transportable system to obtain combined electrical power and heat, and valuable co-products from wood and other biomass fuel. The co-products are high value charcoal, biochar for soil improvement and a means of long term carbon sequestration, and preservatives for building products. Centralised biomass CHP systems cannot address this market. A transportable system is needed to operate at the biomass source and remove the transport costs of bulky wood and agri-waste. ENTRANCE will modify a biochar retort to supply its hot and calorific exhaust gas to an external combustion (Stirling) engine powered CHP generator, modified for wood pyro-gas. The gas will be storedin a portable buffer gas store to allow continuous electrical output from the biochar batch operation. Innovative compact heat exchangers will be used to cool and densify the hot gas for storage and feed to the Stirling combustor, whilst recyclable filters will be developed to clean the gas and extract valuable compounds. Electricity is for use in agricultural buildings or grid supply, the heat from the exchangers is used for biomass or crop drying.

The PROMENADE (Plasma Removal of Methane from Natural Gas Dual-Fuel Engines) project will demonstrate the use of non-thermal plasma, advanced combustion and control techniques and Additive Manufacturing to allow dual-fuel (Diesel-Natural Gas) to meet Euro Stage VI emissions standard while delivering considerable fuel economy benefits over conventional diesel engines. Johnson Matthey, G-volution Ltd and HiETA Technolgies along with the University of Manchester and Queen's University Belfast, working with MAN Truck and Bus AGwill provide a full scale engine bench demonstration of these combined technologies.

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.

The project aims to develop a novel recuperator technology for stationary power Micro turbine generators. MTGs already have a number of benefits compared to diesel or other reciprocating internal combustion engines (currently used for decentralised power generation) in that they are able to burn almost any gaseous or liquid fuel with significantly improved emissions. However current markets for MTG static power generators are limited by the inherent fuel-to-electrical efficiency, where the recuperator is a key driver of both engine efficiency and cost. This recuperator project looks to address both these issues to substantially increase the decentralised power market opportunity for MTG systems. Through the application of production Additive Manufacturing techniques, specifically high productivity Selective Laser Melting, the project will deliver a highly efficient integrated recuperator at a competitive cost.

This project will assess the technical feasibility of using Additive Manufacturing to make high-temperature air- cooled nickel superalloy radial turbine componentry for automotive applications. This is expected to enable turbine operating temperatures of ~1050C, enabling more extreme downsizing of engines, removing the need for integrated cooled exhaust manifolds and leaving more thermal energy for waste heat recovery post- turbine. The project partners are HiETA Technologies Ltd and the University of Bath's Powertrain and Vehicle Research Centre (PVRC) and Turbomachinery Research Group (TRG).

The project builds on the technology development work being carried out in Innovate UK iBranch project, and will assess the technical feasibility of an Additive Manufactured complex multi-fluid multi-phase heat exchanger for use within an Inverted Brayton waste heat recovery system. The system converts waste exhaust energy from an internal combustion engine into useable power, either electrical or shaft. The heat exchanger aims to significantly increase the energy harvest potential of the system using phase change and multiple coolant loops to optimise the thermal management, and is expected to reduce CO2 emissions by 10%. The partners are HiETA Technologies Ltd, the University of Bath and Axes Design Ltd.

High performance mouldable plastics like PEEK/PEK and others in the polyaryletherketone family (PAEK), and their engineered composites are materials of the future and of particular interested to airframe makers as a metal replacement, being 40 -70% lighter than steel, titanium or aluminum. PAEK composites are also highly corrosion resistant, heat tolerant to 250oC+, don’t burn, and can compete mechanically. Additive Manufacture (AM) of PAEK polymers and composites is now possible, where if this production route could be matured and perfected, AM PAEK would be exploited far more extensively in future aircraft. Similarly to metals AM, which is now an established and indispensable tool in airframe design and manufacture, the usage of PAEKs would grow. This aim is to solve the well identified technical barriers hindering AM-PAEKs exploitation, and thereby make the process, reliable, cost competitive and a common-place fabrication route, available throughout the aerostructures supply chain. This initiative brings together the entire materials & processing supply chain, including polymer makers/suppliers through to parts manufacturers and post-processors as well as end-users.

To develop capability in Computational Fluid Dynamic (CFD) techniques to enable the innovative exploitation of Additive Manufacture technology.

The project will deliver an Exhaust Energy Conversion unit that will convert some of the waste energy in the exahust gases of an internal combustion into useable power, either electrical or shaft. The unit is based on a modified Brayton cycle that uses readily available turbomachinery components in a novel arrangement, together with a heat exchanger that will be designed for rapid manufacture using selective laser melting, a form of additive manufacture that processes metal powders. Initial 1-D modelling suggests that at full power the fuel savings and CO2 emissions reductions can be 10-12% using standard turbocharger components at reasonable pressure ratios. Considerably higher performance can be achieved with higher efficiency components and high pressure ratios. The partners are HiETA Technologies Ltd (lead), the University of Bath, and Axes Designs Ltd.

The Additive Manufacture for Automotive Fuel-cell Systems (AMAFS) project will demonstrate the advances possible using the design freedoms of Additive Manufacturing to make compact, lightweight and cost effective Automotive Fuel Cell systems. A novel multi-phase heat exchanger will be developed, integrated and demonstrated to yield an automotive fuel-cell system smaller, cheaper and lighter than before.

With valuable knowledge and intellectual property in the area of 3D printing, we also have a high reliance on technology both software and hardware. In this context we believe an effective cyber security strategy will provide us with many benefits. As well as directly protecting HiETA business in terms of current design contracts and development projects. potential investors, customers and suppliers will all be gained through improvement to the cyber security at HiETA.

This project will inspire new design freedoms for Metal Additive Manufacturing (MAM), in particular Selective Laser Melting (SLM), to create advanced lightweight structures and products. A major constraint of MAM is the requirement of support structures for building overhanging geometries. This will be overcome by an innovative CAD/CAM solution which utilises smart “self-support” low-density lattice structures (down to 5% volume fraction) to efficiently support internal and external overhanging geometries of lightweight products. Furthermore, an end-to-end manufacturing simulation and rehearsal tool will be developed to predict the manufacturability and performance of lightweight products and stimulate design freedom and optimisation which can reduce material and production costs for MAM. The aim of this project is to enable the UK automotive, aerospace and engineering sectors to more effectively exploit MAM technologies.

The SLaMMiT (Selective Laser Manufacture Micro-Turbine) aims to develop a new micro-turbine employing Selective Laser Melting, a metal powder bed fusion version of Additive Manufacture. The micro-turbine will initially be targeted at the market for range extenders for electric vehicles, but it will also be suitable for micro-chp, concentrating solar power, and waste heat to power conversion, including automotive auxiliary power units operating off the waste exhaust heat from the vehicle's main internal combustion engine.

The SLaME (Selective Laser Manufacture for Engines) project is designed to exploit the 3-D design freedoms enabled by Selective Laser Melting, a metal powder bed fusion version of Additive Manufacture, in developing SLM components for new lightweight, ultra efficient engines for vehicles, with the aim of contributing to step-change reductions in CO2 emissions. The outputs will include microturbines with SLM components for range extenders for electric vehicles and for Exhaust Energy Recovery engines to convert high temperature e waste exhaust heat from the vehicle's main internal combustion engine to electrical or extra shaft power; a "scroll" engine with SLM components, based on mass produced scroll compressor technology, to act as an Exhaust Energy Recovery Engine for lower temperature exhaust heat up to 400C; and SLM components for internal combustion engines designed to improved cooling and air flow, leading to higher efficiencies.

The High Efficiency END-to-End (HiEND) project addresses the ability of AM to operate as an effective manufacturing route for mid to mass market by proving a viable business/manufacturing model for producing 50,000 units p.a. for our target product within 3-5 year. Once completed we expect to be able to redefine the boundaries of AM capability and the component features that will make it a attractive process. Successful proof is not only that the number of units can be produced but includes achieving production at a competitive cost, quality and with an acceptable performance envelope.

Building on Delta’s TSB-supported feasibility study, the aim of this project is to design and build a small, light weight and most importantly low cost microturbine-based generator for use as a range extender for electric vehicles. The holistic approach taken by Delta to understanding the challenges posed by vehicle electrification has highlighted that a low cost, compact range extender is a very important enabling technology – its addition to an electric vehicle will reduce the vehicle’s cost (by displacing some of the batteries) while also offering its owner greater availability and range. Delta is starting afresh with the microturbine, optimising it for the automotive range extender application. The chosen size of 15kW will allow the device to be extremely compact whilst still delivering sufficient power to cover the vast majority of usage scenarios.

HiETA sees an opportunity to exploit its unique design techniques, IP and license rights based on Selective Laser Melting (SLM) for heat exchangers and engine systems. SLM is a form of additive powder layer manufacturing suitable for high performance alloys and constructing crucial components of heat engines for the automotive sector. There are at least four distinct applications for the new engines: as Auxiliary Power Unit (APU) that can operate either off the exhaust heat of the vehicle’s main internal combustion engine or off a separate fuel supply (mainly large trucks, particularly in the USA); as an APU operating off the main engine’s exhaust heat alone (cars); as an APU operating off the exhaust heat of the Range Extender of an electric or hybrid vehicle; or as a fuelled range extender itself. The functions and benefits include generation of electrical power, elimination of the alternator, reduction in the size of the internal combustion engine needed, improved fuel consumption, and reductions in emissions. Successful development will lead to other opportunities in micro power generation and defence sectors. At present there is limited specialist design and production capability in the UK and for this technology generally and so developing the skill set and knowledge base to improve this situation is an important additional goal.