Metal additive manufacturing is the process of building up parts in a layerwise process, rather than machining them from initial homogeneous bulk material. By selectively adjusting the machine parameters it is possible to include multiple material properties within a single part, enabling a wider range of more optimised designs than has previously been possible. There is an ever-expanding range of Additive processes and materials, enabling totally new performing parts that are lighter and have novel functions. Additive Flow is the leading software provider for multi-property optimisation and has the capability of generating new ways of manufacturing with multi-properties, and multiple process parameters. This is a fresh new area for growth within engineering in the UK and internationally. In order to unlock the potential of this multi-property optimisation, new ways of testing and gathering data for components that have multiple material properties are needed. In collaboration with the National Physical Laboratory a series of multi-property components will be created which will then be tested and the data will be fed back into the existing software that will improve engineering performance and cost savings for manufacturing. Additional benefits include reducing complexity for users within a multi-scale and multi-disciplinary engineering design space increasing accessibility and adoption of new technologies. Additive Flow's optimisation software determines trade-offs between manufacturing speed and cost against the function and performance of the final part. This can allow more novel parts to be produced quicker and more cost-effectively, enabling greater exploitation of the benefits of AM. However, many of the resulting designs result in inhomogeneous material for which accurate material property data is lacking. The lack of data has resulted in sub-optimal optimisation due to the need to be sufficiently cautious to avoid part failure and subsequently the certification is also expensive. This project will take approaches to measure and evaluate the physical dynamic material properties of heterogeneous structures and use this data to validate processing parameters predicted by the digital simulation. Since surface roughness is a major influencing factor for fatigue, different parameters will be explored to purposely exhibit target varying fatigue values enabling AM to take a major step towards controlling fatigue. This has benefits to the development of the UK industry, where the solution would greatly improve design optimisation processes and have positive economic, social, and environmental implications because material wastage is minimised and process failure is avoided.

Metal additive manufacturing is the process of building up parts in a layerwise process, rather than machining them from initial homogeneous bulk material. By selectively adjusting the machine parameters it is possible to include multiple material properties within a single part, enabling a wider range of more optimised designs than has previously been possible. There is an ever-expanding range of Additive processes and materials, enabling totally new performing parts that are lighter and have novel functions. Additive Flow is the leading software provider for multi-property optimisation and has the capability of generating new ways of manufacturing with multi-properties, and multiple process parameters. This is a fresh new area for growth within engineering in the UK and internationally. In order to unlock the potential of this multi-property optimisation, new ways of testing and gathering data for components that have multiple material properties are needed. We generate in collaboration with NPL a series of multi-property components, which will then be tested and the data will be fed back into the existing software that will improve engineering performance and cost savings for manufacturing. Additional benefits include reducing complexity for users within a multi-scale and multi-disciplinary engineering design space increasing accessibility and adoption of new technologies. Additive Flow's optimisation software determines trade-offs between manufacturing speed and cost against the function and performance of the final part. This can allow more novel parts to be produced quicker and more cost-effectively, enabling greater exploitation of the benefits of AM. However, many of the resulting designs result in inhomogeneous material for which accurate material property data is lacking. The lack of data has resulted in sub-optimal optimisation due to the need to be sufficiently cautious to avoid part failure and subsequently the certification is also expensive. This project will take approaches to measure and evaluate the physical material properties of heterogeneous structures and use this data to validate processing parameters predicted by the digital simulation. This has benefits to the development of the UK industry, where the solution would greatly improve design optimisation processes, have positive economic, social and environmental implications because material wastage is minimised and process failure is avoided.

An estimated 2 million people use NHS orthotic services in the UK, with a total spend over £207 million/year. Orthoses are a high-value medical device, however, manufacturing processes have not changed in the last 50 years and as a result, current waiting times for orthotics services are now up to 12 months. Andiamo is the world leader in 3D printed orthotic services. We have the only clinically approved 3D printed ankle-foot orthoses being worn today anywhere in the world. We can deliver an orthosis within 1-week of consultation and are revolutionising orthotics services, however we are limited by current AM machines and a lack of integration and specialisation for medical device production. To solve this problem we have partnered with Medway Community Healthcare, an award winning healthcare provider with numerous NHS service contracts, and The Plastic Economy (TPE), an innovative early-stage company with novel platform technology and manufacturing knowhow. Based on the requirements set out by the BHTA, universal adoption of a service such as we propose, could save the NHS (by 2020) £1 billion every year and lead to an additional 300,000 patients under orthotic care. These patients will realise the benefits of orthotic care, such as improved mobility and quality of life. Post-project, TPE will adapt the platform technology for other medical devices and high-value industries.

3D printing or additive manufacturing is a process of making 3D solid objects from a digital file. In an additive process, an object is created by laying down successive layers of material until the object is created. The 3D printing industry is growing at its fastest ever rate (31.6% CAGR) and is expected to exceed £16 billion in worldwide revenue by 2020. The Plastic Economy is seeking to unlock the true potential of 3D printing with sustainable manufacturing applied to high value products.

The Plastic Economy is working to catalyze sustainable plastics processing worldwide. We are developing technology with the potential for mass-industrial de-carbonisation, cost savings, and improved energy security. Our mission is to accelerate global recycling capacity, by pioneering scalable upcycling at both the community and city levels - and empower localities to harness their waste streams for both social and economic benefit.