On July 10th Innovate UK and the KTN held a business innovation day to showcase 30 of the Innovate UK projects that are currently active in the area of Additive Manufacturing. The presentations and pitches made on the day are now available to download. Topic 3 focuses on Post Processing

1. Topic
3:
Post
Processing
Presenting
Simon
Rogers
Bethany
King
Graham
Robertson
Ben
Farmer
Dave
Cooper
Joseph
Crabtree

2. Project
title:
SEAMLESS
– Digitally-­‐Enabled,
Automated
Post
processing
for
AM
Abstract:
SEAMLESS
is
a
major
upscale
of
FlexiFinish which
focussed
on
the
urgent
issue
of
post
processing
for
AM.
The
key
technology
advances
over
the
FlexiFinish concept
include
super
surface
finishing
(adaptive
shape
grinding)
for
applications
that
require
<0.1μm
Ra
(e.g.
space
and
medical
sectors);
laser
shock
peening for
enhanced
functional
performance
alternative
NDT
solutions
(eddy
current)
for
difficult-­‐to-­‐access
features;
empirical
modelling
/
simulation
tool
for
right-­‐first-­‐time
KPV
identification
(therefore
minimum
or
no
re-­‐work);
offline
programming
for
auto
tool
path
generation
and
a
digital
platform
(cloud)
to
enable
smooth
and
seamless
connectivity
between
the
different
components
of
the
system,
Presenter
name/
company:
Simon
Rogers
-­‐
Project
ref
103274

3. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
•Modularity: Use
of
a
robotic
platform
with
interchangeable
‘Eddy
Current
inspection’,
‘Laser
Shock
Peening’
and
‘Shape
Adaptive
Grinding’
heads
enables
parts
of
almost
unlimited
size
to
be
processed.
•Real-­‐time
insight: Use
of
digital
manufacturing
techniques
and
array
of
sensors
and
software
tools
to
provide
data
both
on
the
process
and
the
quality
of
parts
produced,
both
metallurgy
and
metrology.
•Autonomy:
Digital
information
used
to
enable
the
cell
to
operate
in
an
autonomous
mode,
defining
if
components
need
further
processing
to
enable
‘Adaptive
AM
Post
Processing’
in
the
truest
sense.
•Enriched
modelling: Data
collected
from
the
components
will
be
used
to
adjust
the
tool
path
strategy
/
options
to
give
an
Adaptive
process,
including
environmental
effects
on
the
cell
performance.
• Novel
template
driven
AM
post
process
robot
programming
(PROCESS)
• Automated
toolpath update
based
on
NDT
measurement
(INSPECTION/DESIGN)
• Safer
working
environment
enclosed
(PROCESS)
• Reduced
AM
post
processing
costs
(COST/FINANCIAL)
• Aerospace
and
Medical
Alloy
build
specs
and
standards
(MATERIALS)
• Automated
metallurgy
inspection
and
critical
feature
machining
for
AM
components
combined
(PROCESS)
• AM
build
for
post
processing
access
to
critical
structures
(DESIGN)
Autonomy
Enriched
modelling
Modularity
Real-­‐time
insight
NDT Shape
Adaptive
Grinding
Laser
Shock
Peening
Eddy
Current
Flexible
Media
Workflow
Alicona
Rigid
Media
Project
ref
103274

4. Topic
3:
Post
Processing
Pitches

5. Project
title:
ProAMP
Abstract:
This
project
is
examining
ways
to
improve
the
surface
finish
of
parts
made
by
Selective
Laser
Sintering.
This
will
be
done
at
looking
at
methods
of
improving
scanning
methodologies,
and
developing
an
automatic
SLS
part
finishing
system
with
auto
component
identification
for
packaging.
Presenter
name/
company:
B.
King,
Lancaster
University
Project
ref
103448

6. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
• The
project
is
at
an
early
stage
and
objectives
are
due
in
2020
• Project
will
allow
parts
to
be
unloaded
from
an
SLS
machine,
cleaned,
identified
and
packed
automatically.
• Methods
to
produce
better
surface
finishes
arising
from
new
scan
algorithms
will
be
trialed.
• Software
and
equipment
is
currently
under
design
• Initial
testing
of
both
software
and
equipment
is
expected
in
late
2018
• The
project
contributes
by
looking
at
methods
to:
• improve
finishing
and
part
consistency/quality;
• increase
speeds
of
production;
• reduce
costs;
• Areas
of
research
interest
include
investigations
into:
• better
materials
for
SLS
AM
(e.g PEEK);
• construction
of
large
body
AM
machines;
• automatic,
in-­‐process
feedback
systems;
Project
ref
103448

7. PowderCleanse -­‐ Automated
powder
recycling
and
quality
assurance
for
enhanced
material
reuse
for
AM.
Abstract:
Challenging
“The
way
we’ve
always
done
things”.
Developing
a
closed
loop
powder
management
system
including
powder
validation
which
utilises
digital
connectivity
to
both
monitor
and
control
every
aspect
of
the
process.
Graham
Robertson
(LPW
Technology)
Ben
Blackham
(MTC)
Project
ref
103278

8. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
• Material
alloy
development
• Health
Safety
and
Environment
guidelines
• Recycling
expertise
• Education
and
Training
Materials
and
processes
Inspection,
Test
and
Standards
Process
performance
captured
digitally
Central
data
repository
Project
ref
103278

9. Project
title:
Tailorable
&
Adaptive
Connected
Digital
Additive
Manufacturing
(TACDAM)
Abstract:
The
TACDAM
project
will
perform
targeted
Additive
Manufacturing
(AM)
pre-­‐ and
post-­‐process
value
chain
technology
developments,
develop
an
adaptive
quality
assurance
model,
introduce
parametric
design
as
a
key
process
variable
and
demonstrate
the
capability
to
deliver
cost
and
quality
outcomes
at
Manufacturing
Readiness
Level
6
to
the
automotive
industry.
Presenter:
Dr Ben
Farmer
/
HiETA Technologies
Ltd
Project
ref
103279

10. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
• £
Automotive
&
staged
1/3/6s quality
• Machine
learning
to
facilitate
automation
reduce
cost
and
variability
• Design:
Quantification
of
the
performance/yield
trade
off
• Materials:
More
cost
effective
Inconel
&
titanium
• Inspection:
Non-­‐contact
inspection
to
establish
that
powder
is
removed
• Supply chain:
Industry
vertical
• Design
methods
and
tools
• Physics
and
AI-­‐based
modelling
for
design
and
manufacturing
• New
Al
and
Ni-­‐based
materials
• NDT/NDI
of
complex,
dense
parts
• Automation,
simulation
and
optimisation
of
future
industrial
environment
• Parametric
design
as
a
key
process
variable
• Started
at
MRL3,
currently
MRL5,
finish
at
MRL6
OperationsDesign
Concept design
AM process
selection
Detailed design, optimisation,
DFM
Build design
and
preparation
Material
Process and post-process Quality assurance
AM process
Powder
removal
Heat &
pressure
treatment
Removal from
plate
Support
removal
Machining and
smoothing
Surface
treatment
Destructive
testing of
traveller
NDT/NDI Finished part
Validation
testing
Maintainence Overhall Repair
£££ ££ £ ££ £ ££Cost
challenges
Quality
challenges
££
Project
ref
103279

11. Automated
Post-­‐Processing
Platform
for
Metals
Additive
Manufacturing
– (PLATFORM)
One
of
the
key
technical
challenges
facing
the
metal
AM
market
is
the
need
for
post-­‐processing
of
parts
to
achieve
required
tolerances.
The
PLATFORM
project
aims
to
revolutionise
the
way
in
which
metal
AM
products
are
finished
by
developing
a
modular
system
and
automatic
CAM
software
for
support
removal
and
proof
machining.
Dr.
Dave
Cooper
– Progressive
Technology
Project
ref
103453

12. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
• Deliver
a
modular
work
holding
system
to
enable
end
to
end
complex
AM
part
production
and
reduce
fixture
costs
• Automate
CNC
support
removal
&
proof
machining.
• Combine
with
efficient
CT
techniques
to
aid
alignment
of
machining
to
blanks
and
reduce
setup
time/scrap
• First
steps
toward
AM/CNC
integration
have
begun
• Key
issues/likely
problems
are
beginning
to
be
understood
• Streamlines
production
of
high
value
machined
AM
parts
• Reduces
scrap
and
“black
magic”,
lowering
barriers
to
entry
for
SME’s
• Integration
of
AM
into
post
processing
supply
chain
Project
ref
103453

13. AMSURFIN
-­‐ Additive
Manufacturing
SURface FINishing -­‐
An
automated
intelligent
solution
for
polymer
parts
The
project’s
vision
is
to
create
an
automated
intelligent
post
processing
machine
capable
of
finishing
additively
manufactured
thermoplastic
polymer
parts
to
an
injection
moulded
level
surface
finish.
Joseph
Crabtree
/
Additive
Manufacturing
Technologies
Limited
Project
ref
103275

14. Project
Objectives
Your
requests
to
UK
Research
(Universities,
UKRI)How
does
this
contribute
to
delivering
the
AM-­‐UK
Strategy?
Progress/
Learning/
Outcomes
1. Create
a
saleable
automated
post
processing
machine
capable
of
generating
a
repeatable
and
reproducible
surface
finish
equivalent
to
that
achieved
in
injection
moulding
for
additively
manufactured
parts.
2. Develop
intelligent
algorithms
that
control
the
amount
of
post
processing
for
a
given
material
and
geometric
design.
3. Develop
a
machine
that
is
integrated
into
the
digital
manufacturing
chain.
1. Directly
addresses
the
issue
around
the
optimisation
and
automation
of
Post
Processing
in
3D
Printing.
2. Protected
by
IP
and
CE/UL
Standards.
3. Industry
4.0
compliant.
1. Understanding
the
total
value
chain
proposition
from
Materials
à parts.
2. Application
and
Industry
4.0
relevant.
3. Must
have
‘hands
on’,
practical
approach.
Project
ref
103275