Global Expert Mission Composite Materials in the USA

Dallas, Knoxville, Huntsville | 15th – 19th October 2018

Innovate UK’s Global Expert Missions

As innovation is increasingly a global endeavour and the ambition of UK businesses to become truly international enterprises is at its highest, Innovate UK has launched its new Global Expert Missions. Delivered by the Knowledge Transfer Network (KTN), the Expert Missions will help further Innovate UK’s global strategy by providing the evidence base for where it should invest and by providing the opportunities for UK businesses to build partnerships and collaborations with key economies.

Built around UK business, policy and research representation, an Expert Mission aims to achieve the following objectives:

1) To gather market insights and to build expert foresights on new and emerging innovation sectors, in order to ascertain quantifiable benefits and synergistic strengths between the UK and a Partner Country. 2) To build a portfolio of technological and business priorities as the foundation that elevates the UK as the “partner of choice” in future innovation partnerships with strategic global economies. 3) To explore and identify effective and sustainable collaboration model(s) with a Partner Country in specific growing sectors. 4) To set up the groundwork and early dialogues for UK business community to catalyse future internationalisation opportunities. 5) To help align innovation policy direction and unlock regulatory barriers for future international partnerships.

1

USA-UK Composite Materials Expert Mission

As part of our activities to continue to build on the strong innovation capability of the UK Composites and Composites Materials Sector, Innovate UK is sponsoring an Expert Mission to the US.

The aim of the Expert Mission is to better understand the US Composites and Composites Materials innovation landscape, benchmarking against our UK capability. Outcomes of the Mission could be a more robust case for proposed public/private investments in the UK, or opportunities for the UK to collaborate with best in class US companies or organisations.

The Mission includes experts from Industry, Government and Academia.

It will take place in the week commencing 15th October 2018 to include attendance at the CAMX Conference in Dallas.

Mission Contact Details

UK USA

Callum Harvey Laura McAllan Mission Lead Department for International Trade Knowledge Transfer Network British Consulate General Houston, TX e: [email protected] e: [email protected] m: +44 7875 225 715 m: +1 832 319 0640

Ajay Kapadia Sarah Banks Technical Lead Department for International Trade Knowledge Transfer Network British Consulate General Atlanta, GA e: [email protected] e: [email protected] m: +44 7964 566 380 m: +1 404 358 2491

2

UK Composite Materials Sector Representatives

Composites UK

Stella Job Job title: Supply Chain and Environment Manager

w: www.compositesuk.co.uk e: [email protected] m: +44 7511 656 088

Composites UK is the trade association for the UK composites industry, with a fast-growing membership, currently around 350 organisations across the UK composites supply chain. The association acts to encourage continuous growth and development of the industry, promoting the best practice use of composites materials. Its role is to bring companies throughout the supply chain together creating partnerships, as well as creating a unified voice to drive the industry forward, benefiting all of those involved.

Composites UK is keen to develop global collaboration opportunities for our members in both manufacturing and research and is increasingly working internationally with ACMA and other associations in areas of sustainability and standards development.

Stella began her career as a civil engineer and later moved into advanced materials. She has worked for Composites UK since 2013, in addition to consultancy work. She is active in supporting supply chain development in composites through introductions, events, information and direct support to companies. She chairs the Composites Leadership Forum Sustainability Working Group and works to progress strategic environmental development in areas such as recycling, bio-based materials, life cycle assessment.

Stella has four children and enjoys making things, including converting a campervan which includes a part-recycled GRP roof, and leading a church youth group.

3

Department of International Trade (DIT)

Faye Smith Materials Specialist

w: gov.uk/dit e: [email protected] m: +44 7920 213 494

The UK Government’s Department for International Trade (DIT) promotes British trade and investment across the world, supports foreign direct investment into the UK and is delivering a new trade policy framework for the UK as we leave the EU.

Faye Smith, DIT’s specialist in composite materials and foreign direct investment, supports the Composites Leadership Forum’s work to deliver the UK Composites Strategy through supply chain development. She works with overseas-owned companies to set up and/or grow their UK presence, be that R&D, manufacturing or sales, through understanding of the market and support opportunities within the UK-based composites supply chain. DIT also then supports any company with UK-based capability/production to export their products globally.

Faye is interested in talking to any non-UK owned company who has an interest in operating within the UK’s composite materials supply chain. DIT has supported recent investments by the likes of McLaren Automotive (£50m and 200 jobs in a Composites Technology Centre) and Hexcel’s £7.4m, ATI supported, R&D project to develop cost effective composite materials and manufacturing techniques.

4

Formaplex

Matt Sellens Sales Director Specialist Engineering Division

w: www.formaplex.com e: [email protected] m: +44 7703 680 072

Established in 2001 Formaplex is now a leading UK manufacturer of tooling and lightweight component solutions turning over £60M and employing over 600 people.

With a reputation for excellence built on decades of engineering experience and a dedication to dynamic working practices, we supply our clients with an innovative and industry-leading service. We work with clients across Automotive, F1, Aerospace and Defence markets who operate at the very top of their fields. In an environment where exceptional performance is a given, our high speed machining technology and unparalleled expertise in both engineered polymers and composites, sets us apart.

Formaplex has 260,000 sq ft of shop floor space across 4 sites with over 50 CNC machines, 18 injection mould presses ranging from 50t to 3,500t, aerospace grade cleanrooms, 3 autoclaves & 2 vertical presses.

Matt is an experienced, chartered engineer with 20 years employment history in Automotive OEM, Engineering Consultancy and Manufacturing environments. A background in the development of automotive structures has given him a strong grounding for the lightweight automotive challenges that Formaplex are now able to address with composite solutions.

Matt joined Formaplex 5 years ago as Business Development manager in the brand new composites division. Since then this division has incorporated a range of Specialist Engineering functions and expanded the team to 150 people. SED recently took delivery of a 600t vertical press for high volume composite production development. This was installed in a newly established 27,000 sq ft Composite R&D Centre and will be joined by 2 new autoclaves and 2 new cleanrooms. The team has been involved in a number of collaborative R&D projects in the UK to develop high volume manufacturing processes such as HP-RTM.

Formaplex is established in the UK Automotive and Motorsport composite and engineered polymer market and is a significant buyer of polymers, prepreg laminate, dry woven materials, tooling block and resins.

The next opportunity for Formaplex is expanding its export markets with the potential to establish an international presence.

5

GKN Aerospace

Craig Carr Composites Technology Manager

w: www.gknaerospace.com e: [email protected] m: +44 7557 015 161

GKN Aerospace is the world’s leading multi-technology tier 1 aerospace supplier. With 51 manufacturing locations in 14 countries, we serve over 90% of the world’s aircraft and engine manufacturers. We design and manufacture innovative smart aerospace systems and components. Our technologies are used in aircraft ranging from the most used single aisle aircraft and the largest passenger planes in the world to business jets and the world’s advanced 5th generation fighter aircraft. GKN Areospace is a member of Advanced Manufacturing Research Centre with Boeing.

Craig Carr is postgraduate qualified with 22 years in the Aerospace Industry, Military & Civil. Responsible for Composites Technology Cluster GKN Aerostructures – Europe & Asia. Chair of the Aerospace technical advisory group for the National Composite Leadership Forum. JEC, IET Patent award winning technical capability. Steering Board Member for the Advanced Composite Manufacturing Hub (EPSRC). Member of the NCC & AMRC research operations Committee. IMechE UAS Challenge Judge.

Our products and services related to the areas covered in this Mission are: Pre-impregnated and Resin infusion technologies, Automated Fibre & Tape Placement, Automated Assembly, Trans Lamina Reinforcement techniques, sandwich structures, repeatability and repair issues, NDT, Finite Element Analysis for spring back, component design, tooling, process methodology, control instrumentation and materials.

Our current growth and investment/funding stage of business is to sustain and position GKN by provision of global technology centre based in the UK for open collaborative development of key capabilities.

Internationally, our growth plan is to position GKN to support the Next Single and Multi aisle aircraft projects.

We have discussions ongoing and requested for improving UK/US collaboration and program opportunities.

6

National Composites Centre (NCC)

Mark Bowering Chief Technologist

w. www.nccuk.com e. [email protected] m. +44 07807785661

The NCC provides industrial scale Research and Technology Development facilities to meet the needs of all sectors wishing to capitalise on the high-strength, low weight, corrosion-resistant qualities of composites materials.

The NCC is hosted by the University of Bristol and works closely with EPSRC Centre for Innovative Manufacturing in Composites to evolve and mature emerging composite manufacturing technologies from the laboratory through to commercial maturity.

Mark is Chief Technologist of the National Composites Centre in Bristol. He has extensive experience in defining and leading composites and technology development and after spending a few years as Head of Engineering at the NCC he now has responsibility as Engineering Architect for major Aerospace and multi-sector programmes. He is experienced in realising multi-disciplined engineering concepts and developing composite manufacturing methods, including HPRTM, automated deposition, preforming, large scale resin infusion, RTM, prepregging and thermoplastic composites processing.

He has been involved in composite technology and capability development for nearly twenty years and has held a number of senior engineering positions including Head of Engineering, Manufacturing Capability Manager and Transnational Manufacturing Leader in large commercial and research organisations. Mark is a Board member of the AGP Manufacturing Working Group and the Aerospace Strategic Sector Team. In recent years, he has led several multi-million pound research programmes involving the engineering development and manufacturing of full scale aerospace composite demonstrators; adopting and developing engineering techniques, advanced materials and manufacturing methods.

7

Sigmatex

Paul McMullan Global Commercial Manager

w: www.sigmatex.co.uk e: [email protected] m: +44 7715 674 901

Sigmatex are leaders in the supply of carbon fibre textiles to the composite industry. With over 30 years’ experience, we have developed an enviable reputation for quality, service and innovation. We are a truly international business with 4 manufacturing locations (2 in the US) and a global network of customers from markets covering Aerospace, Automotive, Marine, Wind Energy and Sports & Leisure.

As the Global Commercial Manager for our business my main responsibility is to profitably grow our business within our key markets and territories. We are a highly ambitious business, with an unrivalled range of technologies and products. Our preferred business model is to form partnerships with our clients, working closely together to achieve an optimal solution.

At Sigmatex we invest heavily into R&D for this very reason, we want to be leaders in the evolution of CFRP through the creation of more advanced material architectures to meet the challenges of tomorrow. Part of my interest in this mission is to promote our R&D activities and new products to a new audience, to raise awareness and generate interest that may lead to new partnerships. We have a constant conveyor of new products coming through our business! In addition, I also wish to learn more about the market, and specifically the US market for Aerospace and Automotive. The insights I gather will undoubtedly influence our business strategy and shape our commercial plans. We have a strong desire to work collaboratively with other like minded businesses.

Our business currently has revenues of $85M globally, with 4 manufacturing locations (UK, California, South Carolina and China). We are a privately owned business and investment orientated – all our facilities are modern 1st class manufacturing plants equipped with state of the art machinery. We expect to continue to grow significantly over the next 5 years and anticipate to add further plants and equipment to support capacity expansion.

We are currently an established international business with production in UK, USA & China. We are highly interested to collaborate with the US – both through our UK Innovation centre and at a regional US plant level. We have significant research and development activities that offer huge potential for collaboration. The opportunity to make this possible is part of my objective on this mission.

• In last 12 months we have secured major customer contracts worth over $200M • We have achieved AS9100 rev D across UK & US plants • We have been awarded Jaguar Land Rover innovation award • We have been awarded the Composites UK industry award for Environmental sustainability for our novel recycled carbon material • We led and successfully completed the UK government funded project ‘Lightweighting Excellence’ – developing a UK supply chain solution for CFRP components to the automotive industry • We will shortly complete the Innovate UK funded program ‘Breakthrough Aerospace Materials’, which will develop the model for adoption of 3D near net shape textiles for composite structures in Aerospace

8

Surface Generation

Ben Halford CEO / Founder

w: www.surface-generation.com e: [email protected] m: +44 7941 517 163

Surface Generation is a 16-year-old company which offers customers in Aerospace, Automotive, Consumer Electronics, and Energy Advanced Thermal Processing, solutions for the Out-of-Autoclave production of thermoset & thermoplastic composites.

We produce a patented suite of rapid heat cool composite processing solutions for applications including tools / presses / automation for injection moulding, compression moulding, single sided vacuum bag processing and 3D printing.

As our business has developed, we have moved beyond prototype / low volume runs to series production in a range of lightweight / advanced manufacturing applications.

Our current growth stage of the business is to look for additional end user and supply chain partners.

Internationally, we wish to target OEMs to optimise products for advanced processing through design for manufacture and materials optimisation to give step changes in cost / quality / performance.

Our interest in collaborating with the US is to address IP sensitive, on-shoring, ITAR applications over a 5-year timeframe.

9

University of Nottingham & EPSRC Future Composites Manufacturing Research Hub

Nick Warrior Professor, Director of The EPSRC Future Composites Manufacturing Research Hub

w: https://cimcomp.ac.uk/ e: [email protected] m: +44 7771 388 704

Professor Nick Warrior is the Director of The EPSRC Future Composites Manufacturing Research Hub. He has been Head of the Composites Group in the Faculty of Engineering at The University of Nottingham since 2009.

He aims to use the mission to fact-find on US research in manufacturing processes and design and test methodologies of high performance polymer composites for automotive and aerospace applications.

The Hub represents the UK composites research community and we aim to use the mission to meet similar US research organisations.

We aim to work with US researchers to develop international research collaborations and researcher networks.

We aim to develop collaborative research programmes in technologies principally in areas of tapes, textiles and moulding compounds.

Nick has worked on many EPSRC, TSB and industrial composites projects (portfolio value of over £33 million) and has published more than 200 papers in composites and solid mechanics. He has supervised over 40 successful PhD projects. In his research he has worked with most of the UK automotive manufacturers and collaborated with many leading UK universities.

He is a Chartered Engineer and a Fellow of the Institution of Mechanical Engineers and has received the Royal Academy of Engineering Silver Medal Award (2009) for successful industrial exploitation of composite materials.

10

Victrex

James Myers Head of R&D – Aerospace / Composite Applications

w: www.victrex.com e: [email protected] m: +44 7785 476 236

Victrex is a world leader in PEEK (Poly-Ether-Ether-Ketone) and PAEK (Poly Aryl Ether Ketone) based polymer solutions. With more than 35 years of experience, Victrex serves a diversified range of markets and offers proven solutions backed by unparalleled expertise. Leading companies partner with Victrex to drive new technologies and shape future performance.

I am a Chartered Engineer and member of the Institution of Mechanical Engineers and Royal Aeronautical Society. Currently working within Aerospace Research & Development, my career to date has focussed on product development and leading teams engaged in the development of advanced fibre reinforced materials and structures across several multinational businesses of varying size ranging from 900-30,000 employees. My previous roles have focussed upon management and development of teams involved in R&D, advanced product development and realisation, predominantly across the Aerospace sector but also covering Automotive, Rail and Power Generation. A graduate of Aerospace Engineering from UMIST in Manchester, United Kingdom, I obtained a Master of Philosophy in Design & Manufacture and a PhD in Engineering, both from the University of Manchester in the UK.

Current interests are particularly focussed around automated processing and manufacturing techniques for composites structures, cost effective ATL (Automated Tape Laying), over-moulding, hybrid and multifunctional structures. Continuous fibre Additive Layer Manufacture (ALM), high temperature polymer ALM and ‘complex’ core structures are also of interest. Process characterisation (particularly for over-moulding) is of particular interest. Skills and competency development is also an area of importance.

Victrex is actively involved in expansion within the US (Joint Ventures / acquisitions in Rhode Island (TxV – JV with Tri-Mack) and Wisconsin (acquisition of Kleiss Gears) are recent examples). The US is of interest within our Aerospace and Automotive business units and we are keen to understand further options for development within the US market, either via direct expansion, JV or M&A activity within the next 5 years.

Development of links with governmental and research organisations within the US is of interest, as are developing relationships with universities particularly with Purdue, Georgia Tech and MIT.

Our recent developments in the US, particularly with our TxV JV with Tri-Mack in Bristol, RI have shown particular promise and is helping Victrex to develop a larger footprint within both the continental US, and the wider parts market alike as we integrate further into the supply chain.

11

Expert Mission Organisers

Innovate UK

Malcolm Hannaby Innovation Lead – High Value Manufacturing, Process Industries

w: www.gov.uk/government/organisations/innovate-uk e: [email protected] m: +44 7552 267728

Brendan Vickers Partnership Manager – North America

w: www.gov.uk/government/organisations/innovate-uk e: [email protected] m: +44 7767 606867

Innovate UK is the business arm of UK Research and Innovation, the organisation that brings together research and innovation funding. Innovate UK helps businesses to identify the commercial potential in new technologies and turn them into the new products and services that will generate economic growth and increase productivity. With a strong business focus, we drive growth by working with companies to de-risk, enable and support innovation.

To do this, we work to: • Determine which science and technology developments will drive future economic growth • Meet UK innovators with great ideas in the fields we’re focused on • Fund the strongest opportunities • Connect innovators with the right partners they need to succeed • Provide access to state-of-the-art facilities and expertise to commercialise new ideas through our Catapult programme • Help our innovators launch, build and grow successful businesses

Since 2007, we have committed over £1.8 billion to innovation, matched by a similar amount in partner and business funding. We have helped more than 7,600 organisations with projects estimated to add more than £11.5 billion to the UK economy and create 55,000 extra new jobs.

We support UK business-led innovation to explore global opportunities through a range of connecting and funding programmes, including the Newton Fund and European Funding Programmes including Horizon 2020, Eurostars and Eureka. We have supported UK organisations access over 75 international markets.

12

Malcolm Hannaby Malcolm Hannaby, Innovation Lead – HVM for the Process Industries, has over 30 years of experience in the Chemical & Process Industries. During this time he has held a range of business management, technical, marketing and strategic planning roles in all three regions of the world. Most recently he was responsible for Global Strategic Planning at a US based Chemical Multinational, developing strategy and implementing M&A and major investment projects.

This is his second time working for Innovate UK, the first being in 2011 – 13, where he is now responsible for the Chemical, Chemical Using and Process Industry manufacturing portfolio. Malcolm received his BA & PhD at Cambridge University and his MBA from the Open University and is currently based in London, UK.

Brendan Vickers Brendan is a specialist in the management of government funded economic growth programmes focusing on innovation at national and international levels. He joined Innovate UK in April 2013, initially to manage the Home Office and MOD SBRI programmes; facilitating over 80 R&D funding competitions across a wide range of technology areas including those in Aviation Security, Counter Terrorism and Defence.

In November 2017, Brendan took on a brand new role, managing Innovate UK relationships across Canada and the USA. He takes the lead on developing and maintaining relationships with stakeholders and potential partners across Canada and the USA. Potential partners include government departments, businesses, the research communities and business support organisations operating in those sectors and technology areas of strategic importance to the UK.

Prior to this, Brendan had a long and successful career with the innovation company, Pera International, where he was Managing Director of their Global Knowledge and Enterprise Division with responsibility for delivering high-value programmes and for managing the relationship with UK government departments covering Business, Industry, Energy and Trade & Investment.

Internationally, Brendan has carried out projects on behalf of the European Commission and the governments of Cyprus, Egypt and Ireland and operated independently as an Adviser to a New York based alternative origination Investment Company. He also served for 5 years on the board of the Asia Pacific Technology Network.

Brendan is an Incorporated Engineer, a Member of the Institution of Engineering and Technology and a Member of the Institute of Directors.

13

Knowledge Transfer Network (KTN)

Callum Harvey Mission Lead Knowledge Transfer Manager

w: www.ktn-uk.org e: [email protected] m: +44 7875 225 715

Ajay Kapadia Technical Lead Knowledge Transfer Manager – Advanced Composites

w: www.ktn-uk.org e: [email protected] m: +44 7964 566 380

The Knowledge Transfer Network (KTN) is an impartial, not-for-profit organisation that provides innovation networking for other funders in line with its mission to drive UK growth.

We work closely with Innovate UK – the UK’s primary innovation agency – as well as government departments and industry leaders. We also work to strengthen research and innovation partnerships between the UK and economies around the world.

KTN connects UK business to game-changing collaborations. We host horizon-expanding events and provide bespoke support and innovation insights. We link new ideas and opportunities with expertise, markets and finance through our network of businesses, universities, funders and investors. We help business to strengthen the economy and improve people’s lives by capturing maximum value from innovative ideas, scientific research and creativity.

In addition to industry links in emerging industries across sectors the KTN has contacts to universities across the UK to track and commercialise innovations that come out of the research base and helps to commercialise these.

There two KTN initiatives involving composites at the moment:

1. Materials for Composites Special Interest Group – which is looking to establish better links between the chemicals sector and composites to exploit opportunities in end user markets - a number of events and workshops are planned. 2. Joining of Composites Conference being organised in Belfast on 21 March 2019.

Callum Harvey Callum’s focus on Livestock and Aquaculture involves helping not only those from the traditional agriculture landscape, but also increasingly those from outside the sector, to support innovation across the livestock industry. He has been involved in numerous Expert Missions in this area, and has used these experiences to lead on the organisation of others outside of Agriculture.

14

Callum has a background in animal health and production, with an MSci in Veterinary Bioscience. Prior to joining KTN, he led R&D projects across different areas (nutrition, health and technology) and species at a leading animal nutrition company.

Ajay Kapadia Ajay is an integral member of the Materials team at KTN. He has been working with composite materials for over 20 years across a number of industry sectors, including aerospace, oil and gas, construction and marine. He specialises in process development stage of manufacturing, and prior to joining KTN, he established a composites programme at TWI. Ajay is a fluent French speaker and holds a Master’s degree in Advanced Manufacturing Systems.

At the KTN, he helps businesses innovate through networking and helps facilitate the exploitation to R&D through business take up.

15

Department for International Trade, USA

Laura McAllan Trade Investment Associate - Life Sciences and Advanced Engineering and Manufacturing British Consulate General Houston, TX

w: https://www.gov.uk/world/organisations/british-consulate- general-houston e: [email protected] p: +1 832 319 0640

Sarah Banks Trade Investment Associate - Advanced Engineering and Manufacturing British Consulate General Atlanta, GA

w: https://www.gov.uk/world/organisations/british-consulate- general-houston e: [email protected] p: +1 404 358 2491

Ian Stewart Vice Consul Trade & Investment, Southeast USA British Consulate General Atlanta, GA

w: https://www.gov.uk/world/organisations/british-consulate- general-houston e: [email protected] p: +1 404 789 7141

The Department for International Trade (DIT) helps UK-based companies succeed in the global economy. They also help overseas companies bring their high-quality investment to the UK’s dynamic economy, acknowledged as Europe’s best place from which to succeed in global business.

DIT offers expertise and contacts through its extensive network of specialists in the UK, and in British embassies and other diplomatic offices around the world. They provide companies with the tools they require to be competitive on the world stage.

The team in the United States works to promote UK-US trade and investment through offices at the British Embassy in Washington as well as the British Consulates General in Atlanta, Boston, Chicago, Houston, Los Angeles, Miami, New York and San Francisco.

16