This document summarizes the output of the first thought leadership workshop for a new AM processes cohort organized by KTN on November 29th 2018. It lists the attendees from industry and academia working on various AM technologies. The workshop included introductory presentations on different AM processes which generated comments and discussion around issues like cost modelling, residual stress management, and potential applications. Ideas were generated around directions for the UK's position in advancing new AM processes, which were developed into concepts focusing on areas like business models, sector focus, materials and process reliability, and organized R&D. Further discussion focused on sharing information across the cohort, identifying other relevant participants, and mechanisms to facilitate projects collaborating going forward.

1. @KTN_AMSIG
Storyboard
Cohort: New AM Processes
1st Thought Leadership Workshop Output: Thurs 29th November 2018

2. Attendees
• Will Richardson – Reliance Precision: MIRIAM
• Anita Ward – TWI: EB WIRE
• Simon McCaldin – TWI: OAAM
• Nick Allott – nquiringminds: DREAM
• Sarah Karmel – Photocentric: DEV 3DP
• Dan Mace - Archipelago: SMART DROP
• Guy Newcombe – Archipelago: SMART DROP
• Richard Cooper – KTN (Host)
• Rachel Park – Consultant to KTN
• Robin Wilson – Innovate UK (Co-host)
• Gerard Davies - EPSRC (AM Lead)
• Dave Brackett – MTC (National Centre for AM)
• James Hunt – AMRC (Head of Strategy for AM)
• Chris Hargreaves – Addition Design
• Phill Dickens – Added Scientific/University of Nottingham
• David Butler – National Physical Laboratory (AM Science Area Leader)
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3. Background
The cohorts will have objectives in:
• establishing ground rules necessary for successful cohort engagement.
• pushing the boundaries of innovation, sharing leading-edge knowledge.
• generating content for guides and standards around materials, equipment and
processing.
• identifying gaps in knowledge and barriers to commercialisation.
• encouraging more effective networking and new collaborations.
• knowledge transfer (inc. publishing) for wider access where appropriate.
• respecting confidentiality and commercial interests of participating organisations.
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4. Introductory Presentations
1. Will Richardson – Reliance Precision: MIRIAM
2. Anita Ward – TWI: EB WIRE
3. Simon McCaldin – TWI: OAAM
4. Nick Allott – nquiringminds: DREAM
5. Sarah Karmel – Photocentric: DEV 3DP
6. Dan Mace - Archipelago: SMART DROP
7. Chris Hargreaves – Addition Design
8. Phill Dickens – Added Scientific/University of Nottingham
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5. Introductory Presentations - Comments
1. Will Richardson – Reliance Precision: MIRIAM
2. Anita Ward – TWI: EB WIRE
‒ Would like to understand the cost base of the EB-wire process. Is it economically viable for the industries
mentioned? (J Hunt, AMRC)
‒ How does it compare to other processes such as WAAM in terms of residual stress and microstructure? (J Hunt,
AMRC)
‒ How does emissivity of pyrometer vary? (a) in vacuum (b) at the melt pool? (S McCaldin, TWI)
3. Simon McCaldin – TWI: OAAM
‒ Cost modelling of competing processes? (J Hunt, AMRC)
‒ Thermal and residual stress management (J Hunt, AMRC)
4. Nick Allott – nquiringminds: DREAM
5. Sarah Karmel – Photocentric: DEV 3DP
‒ Would you be interested in enabling embedded wiring within parts? (J Hunt, AMRC)
6. Dan Mace - Archipelago: SMART DROP
7. Chris Hargreaves – Addition Design
8. Phill Dickens – Added Scientific/University of Nottingham
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6. Generating a Concept fan
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Ensuring the UK establishes its correct
position in the advancement of new AM
processes

7. Generating Directions
• Diverse applications - Focus on application field e.g. aerospace, medical
• Wider structural advancement of ecosystem – the balance between push and pull
• Use catapults to mature technologies
• Focus on a specific technology
• Focus on error tolerant applications
• Crosscutting technologies - Awareness of competing technologies
• Focus on reducing the cost per part
• New processes should tackle customer issues: How can they use AM?
• Quantify the value network and backtrack to UK pounds
• Consider time to implementation – 2 years and 10 years.
• Deliver on two-year implementation which are closer to market to get quick wins
• Develop the technologies in the UK and help with stickiness.
• Established companies to be bought out
• Compare to Israel where technology is developed and sold. Academic collaboration is also much closer.
• University structure is getting in the way of AM process development, in particular IP. - new processes in
Nottingham and Cranfield.
• AM is just another manufacturing process (c.f. Semiconductor roadmaps – outlet for technologies)
• Invest more versus selected winners
• Benchmark against other countries
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Focus on Target
Sectors
Focus on Grand
Challenges
Focus on new
business models
Focus on 2-yr implementation
to get quick wins
Focus on reliable materials and
properties in the current processes
Focus on cost and
reproducibility
Carry on inventing

8. Generating Concepts
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9. Concept Fan
@KTN_AMSIG
Ensuring the UK establishes
its correct position in the
advancement of new AM
processes
Focus on sector
Mobilise sector councils and trade associations to get sector buy-in
Sectorwise dissemination
Identify 3 to 5 target sectors
Create framework for sector wise roadmap
Focus on new
business models
Develop different business models for different scenarios
Sector specific business models
Focus on UK wrong proven business models
Connect stakeholders: universities, Catapults and companies
Focus on mass production
Identify business models and understand them
Focus on the low-volume high-value manufacture
Focus on 2-year
implementation which
are closer to market to
get quick wins
Focus on reliable materials and
properties in the current
processes
Success is application/ sector specific
Quality assurance and appropriate characterisation techniques
Educating approval/ qualification bodies
Holistic outcome based on a number of inputs (1) Materials (2)
processing method (3) part design (4) process parameters
Focus on grand
challenges
Focus on cost and
reproducibility
Carry on
inventing
Work on patent pooling to allow innovations to coalesce or cross
license
Push forward in an organised/ orchestrated way with associated support
More focus on application and needs from the process the (link to market)
Prioritise on some key targets processes and applications types
Key Issue
Directions Concepts
Ideas 1
Ideas 2
Ideas 3
Ideas 4

10. Ideas 1 – Direction: Business Models, Concept : Sector specific
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Hitching on other
companies printing facilities
(low volume)
Engage with companies that
would understand the
business cases for their
sector/application
Third party production and
delivery (DHL)
Final applications that are
simple and cheap to deliver
Create nationally accredited
case studies for each
sector/business case
Run pilot programmes is to
try them out at scale
Talk to Tim Minshall at
Cambridge
Copy and paste. Translate
and disseminate.
Run "sector” focused
programme with a different
range of technologies.
Figure out what works and
what doesn’t.
Cost modelling of
application-specific
processes
Sponsor analysis to evaluate
the impact and use to set
policy
Linking of AM production to
downstream processing
Knowledge sharing of
business models for
different stakeholders
(SMEs, large companies)
Identify the business models
and fund projects that
follow success
Look at where AM delivers
real value added over other
technologies
Luck at weaknesses the
Killing sectors
Identify the blockages that
prevent take of AM in the
different business models
and fun projects that
address those
Learn from business models
for other technologies and
other sectors
Development of working
groups

11. Ideas 2 – Direction: Sector Focus, Concept : Roadmap target sectors
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A conference of disparate
trade groups and identify
(1) groups that are most
enthusiastic (2) groups
where there is most
demand for AM
Event for sector for AM
companies/ universities to
showcase the value of AM
Educated decision makers
on the benefits of AM.
Allow them to realise that it
is worth their time to
investigate further.
Route to enhance skills of
general workers in the area
Needs to be incentivised
“what’s in it for them?”
Personal contacts with key
individuals in bodies
Incentivise organisations to
participate (tax credits)
HVMC can support the
development of sector
specific roadmaps. Come up
with a standard format to
use with different groups
Put them in a room and lock
them up until they’ve done
it – agreed to producing
roadmap for AM adoption
Create/ demonstrate
benefit – identify route to
adoption
Develop sector specific
marketing approach

12. Ideas 3 – Direction: Reliable materials and properties, Concept : QA and
characterisation
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Can research help with this –
‘physics-based quality
assurance’? (Stewart Williams
at Cranfield working on this
for AM)
Educating qualification bodies
Use of in process control and
monitoring the help verify
part quality
Virtual testing to avoid the
need for many hundreds of
coupon tests
More relevant ways of
validating AM parts and
design
More work into obtaining
quality standards materials
Build in a quality assurance/
characterisation requirement
into AM specific grants (like
the digital connectivity
requirement)
Incorporate QA in process
development planning
Develop new techniques for
NDT/NDE
ISO9000 for AM
Real AM parts or relevant
testing coupons
Pooling of Materials test
data. Avoid duplication by
individual companies.
Standard development to
systematic studies
New validation testing
protocols (appropriate to
application risks).
Enforced/risk shared by
government agency
Investigate new online
processes to check material
quality and properties
Long term studies of
materials (2 to 5 years)
Ask Lloyd’s register or similar
organisation to provide real-time
capture for AM production
processes to verify actual design,
material, process type and
process settings used the park
Adjusting testing standards
for AM
Robust process control to
enable predictability of
outcome
Sufficient investment in
understanding which
techniques suit which
applications
Better use of layer by layer
in-process part inspection in
AM process

13. Ideas 4 – Direction: Carry on Inventing, Concept: Organised and
supported R&D
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Centralised resources to
support i.e. directory of
available resources
Restrict public funding of R+I
to only the activities which fall
within an agreed set of priority
areas
1 ‘sector Council’ to ‘adopt’
(adopt a child) a technology
and grow it
Framework for an open
innovation style mechanism
with clear IP/ rules of
engagement
Mechanism(s) for encouraging
out of stealth mode = funding?
Invention definitions -ideas -
proof of concept -prototype -
market testing
Horizontal innovation pair up
companies from different
sectors. This should lessen
commercial sensitivities
Central repository of R&D projects.
To see who else is doing what and
identifying synergies
Need to decide how to identify the
invention/ Technology to push: (1)
quantify project success (2) make
it easier for successful projects to
receive follow-on funding (3) fund
projects on related areas
Create an AM board to oversee
developments and assist in terms
of connections and routes to
implementation (AM National
strategy – ‘establish a single point
of contact’)
Need to control IP aspects of
sharing data/ ideas – patent
pooling?
Networking/ dating site for
technology ideas and
application challenges
More low volume funding into
test rigs trying to prove a
concept – able to get a go/ no
go without investing huge
amount of time or money
Specific/ themed IUK/RCUK
competitions
Organise framework
mechanism (e.g. SIG/ISCF
challenge)
Establishment of regional
integrators to support

14. Discussion on the event and the Cohorts going forward
The first cohort event:
• Complements well the large plenary Nottingham event
• Enables more detail to be discussed compared to the Nottingham event
• Has more areas of overlap when focussed on a specific subject
• Focusses on technical collaboration for commercialisation
o Is there potential to facilitate a pitching session?
o Could it form a steering group on the various AM areas?
• Process centric user groups could also be set up in certain areas e.g. take wire E-Beam and include universities
to develop a common interest group.
• Could also drop down one more level e.g. Material jetting or be grouped by the type of part.
• Two key areas emerged from the day:
1. Process control
2. Thermal management (but not tied to a specific supplier)
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Session facilitated by Robin Wilson

15. Discussion on the event and the Cohorts going forward
Developing the cohort further:
• Sharing information across the cohort
o This could be project specific but also wider.
o People will sensor themselves to avoid any IP issues
o Will help in finding applications for the technology
• Who else could have been there?
o Attendees agreed that Innovate UK has the right to push more e.g. to generate case studies
o There could be one web page for each cohort, but this needs to be managed to avoid it being shared
globally
• What mechanism could be put in place for projects to talk to each other?
o This needs to be incentivised
o Potential to utilise pitching events
o Contact details are also needed to enable off-line discussion
@KTN_AMSIG
Session facilitated by Robin Wilson