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Engineering and Physical Sciences Research Council 15

the science behind The Theory of the hit film’s scientific consultant on Hawking, black holes and hangovers

Additive Manufacturing special; people news; the energy-positive house; Nepal earthquake CONTENTS 3: Mighty bites Limpet teeth might be the strongest natural material known to man 16 4-5: News Recent EPSRC investments 6-7: EPSRC in numbers and stats behind the news 7: How I spend my Annette Bramley, who leads EPSRC’s 9 Healthcare Technologies team, describes her day job 8-11: What we’ve learned Snapshots of EPSRC investments and stories from the world of engineering and physical sciences 12-17: People Movers, shakers and science in action 18-27: The layer The Additive Manufacturing – and EPSRC’s role in driving it forward 28-29: Adding EPSRC- supported researchers are pioneering new uses for Additive Manufacturing – from canine implants to 3D-printed concrete 30-33: i-Robot Behind the scenes 32 at the EPSRC Centre for Innovative Manufacturing in Intelligent Automation 34-37: Hawking, drinking... and 34 bits of string Professor Jerome Gauntlett, scientific consultant on the hit film, The , describes his work, and life as a PhD student in ’s group 38 38-39: International rescue Joshua Macabuag was one of the first international rescuers to arrive in Nepal after this year’s earthquake Editor: Mark Mallett ([email protected]) EPSRC works alongside other Research Councils which have responsibility in other research areas. Design: Rachael Brown ([email protected]) 40-41: Wee will rock you Pee- The Research Councils work collectively on issues of powered urinals get top billing at Contributors: Karen Brakspear; Professor Phill Dickens; common concern via Research Councils UK. To provide Professor Jerome Gauntlett; Joshua Macabuag; Dr feedback on this magazine, and to subscribe to print and/ Glastonbury Festival Katharine Moore; David O’Gorman; Roland Pease; Will or electronic versions of Pioneer, please e-mail pioneer@ 42: In Profile epsrc.ac.uk Professor Karen Stirling Holford, Chair of EPSRC’s Pictures courtesy of thinkstock.com/MovieStillDB.com [email protected] unless otherwise stated. Strategic Advisory Team for Engineering

PIONEER 15 Summer 2015 2 THE BIGGER PICTURE Mighty bites

Limpet teeth might be the strongest natural material known to man. Researchers from the University of Portsmouth have discovered that limpets – small aquatic snail-like creatures with conical shells – have teeth with biological structures so strong they could be copied to make cars, boats and planes of the . The study examined the small-scale mechanical behaviour of teeth from limpets using atomic force microscopy, a method used to pull apart materials all the way down to the level of the atom. Professor Asa Barber from the University’s School of Engineering led the study. He says: “ is a wonderful source of inspiration for structures that have excellent mechanical properties. “All the things we observe around us, such as trees and the shells of sea creatures, have evolved to be effective at what they do. “Until now we thought that spider silk was the strongest biological material because of its super-strength and potential applications in everything from bullet-proof vests to computer electronics but now we have discovered that limpet teeth exhibit a strength that is potentially higher.” Professor Barber found that the teeth contain a hard mineral known as goethite, which forms in the limpet as it grows. He says: “Limpets need high strength teeth to rasp over rock surfaces and remove algae for feeding when the tide is in. “We discovered that the fibres of goethite are just the right size to make up a resilient composite structure. “This discovery means that the fibrous structures found in limpet teeth could be mimicked and used in high-performance engineering applications such as Formula 1 racing cars, the hulls of boats and aircraft structures.” The research, underpinned by EPSRC investment, also discovered that, unusually, limpet teeth are the same strength no what the size. Professor Barber says: “Generally a big structure has lots of flaws and can break more easily than a smaller structure, which has fewer flaws and is stronger… Limpet teeth break this rule as their strength is the same no matter what the size.” The material Professor Barber tested was almost 100 thinner than the diameter of a human hair, and the techniques used to break such a sample have only just been developed.

Left: Jawsome, a scanning electron microscope image of limpet teeth

PIONEER 15 Summer 2015 33 TARGETING INDIVIDUAL PATIENT TREATMENT £270 MILLION FOR QUANTUM TECHNOLOGIES UK ROBOTICS NETWORK £45 MILLION FOR DIGITAL ECONOMY CENTRES

CYBERSECURITY BOOST £42 MILLION THE ALAN TURING INSTITUTE NEWS £20 MILLION BIOTECH INVESTMENT www.epsrc.ac.uk/newsevents/news

Targeting individual patient treatment £45 million for

EPSRC and the Medical Research Council unpleasant patient side effects, as well as DE centres (MRC) are jointly investing £16 million yield economic benefit through a reduction Six new multidisciplinary digital in multidisciplinary research to develop in the number of ineffective treatments. economy research centres, worth molecular pathology tests leading to new The research will be conducted through six a total of £45 million with partner tools that can precisely target individual nodes led by the universities of Edinburgh, contributions, will be created under patient treatment in a wide range of Glasgow, Leicester, , Newcastle the Research Councils UK Digital diseases. The research aims to reduce and Nottingham. Economy programme, led by EPSRC, which is investing £23 million. UK robotics network Working with Innovate UK and other Involving over 150 university, industry UK Research Council partners, the UK and regional enterprise partners, EPSRC has launched a new national Robotics and Autonomous Systems the centres will develop a suite of network to enhance the UK’s ability to innovative digital technologies – from Network will integrate and coordinate develop and exploit the vast potential personalised digital services activities at eight dedicated EPSRC- of Robotics and Autonomous Systems to interactive media in . (RAS). The global market for service and funded RAS facilities, as well as EPSRC industrial robots is estimated to reach Centres for Doctoral Training across Building on previous investments, US$59.5 billion by 2020. the UK. the centres are a joint investment by EPSRC, the Arts and Humanities Research Council (AHRC), Innovate Cybersecurity boost £270 million for UK, the Digital Catapult and others. EPSRC is co-investing with Innovate UK quantum technologies £5 million in a new research and innovation £42 million Turing hub at the Centre for Secure EPSRC is coordinating a £270 million Technologies Innovation and UK Government initiative to establish Institute launched Centre (CSIT) at Queen’s University Belfast. a National Quantum Technologies The Alan Turing Institute, a Programme. £42 million national research centre, The hub, focusing on cybersecurity for has been launched to promote the Smart Cities and the Internet of Things, will The investment is championed by the development and use of advanced be supported by £9 million in core funding Quantum Technologies Strategic Advisory mathematics, computer science, from the university. Board, a joint government, industry and algorithms and Big Data for academic initiative to help build a CSIT will use the investment to build on human benefit. profitable, growing and sustainable UK its industry and academic partnerships quantum industry. Coordinated by EPSRC and worldwide, increasing the projected level headquartered at the British Library, of investment in its research to £38 million The programme includes a national within London’s Knowledge Quarter, over the next five years. network of Quantum Technology Hubs the institute brings together leaders involving 17 universities and 132 companies, in advanced mathematics and £20 million for biotech EPSRC Centres for Doctoral Training and computing science from the five lead feasibility studies. In September 2015, EPSRC is co-investing £20 million in 23 universities, each investing £5 million. EPSRC invested £12 million in 10 Quantum biotechnology projects, from making biofuel The centre will also partner with Technology Fellowships. from household waste to using bacteria to business and government bodies. make the building blocks for new medicines. The Quantum Technologies Programme The centre’s work is expected to represents the biggest single investment in The projects have been funded through encompass a wide range of a disruptive technology of the modern era, the Industrial Biotechnology Catalyst – a scientific disciplines and business and will help transform vital UK sectors – collaborative programme between EPSRC, sectors, combining theory and from finance and telecommunications to the Biotechnology and Biological Sciences practical application. Research Council (BBSRC) and Innovate UK. energy, aerospace and transport.

PIONEER 15 Summer 2015 4 IMPROVING PATIENT WELLBEING £10 MILLION FOR MANUFACTURING THE FUTURE CRUK UPGRADE £40 MILLION FOR SYNBIO £30 MILLION IAA INVESTMENT £10 MILLION FOR INTERNET OF THINGS NEWS £3.7 MILLION MEGA-MICROSCOPE £4.5 MILLION FOR WATER NEXUS

Rehabilitation nation £3.7 million mega-microscope EPSRC is investing £5.3 million in three EPSRC has invested £3.7 million in a new overseen by the Science and Technology university-led healthcare technology super powerful electron microscope that Facilities Council (STFC). projects focusing on improving patients’ can pinpoint the position of single atoms. lives, allowing greater independence and Covering a range of academic research, benefiting those with a wide range of The Nion Hermes Scanning Transmission from developing new materials for space mobility and coordination difficulties. Electron Microscope, one of only three travel to creating a better treatment for in the world, is sited at the EPSRC anaemia, the microscope lets scientists The projects, whose themes emerged SuperSTEM facility at the Daresbury examine how materials behave at a level a during an EPSRC creative workshop laboratory complex near Warrington, million times smaller than a human hair. ‘sandpit’, are led by Newcastle University, the University of Bristol and the University of Warwick, working with 15 other university partners. They include: development of a £10 million for manufacturing the future prosthetic hand controlled by the nervous system; robotic clothing to help people with Ten new research projects to advance The projects include developing thin- walking; and biosensors to monitor how the UK’s manufacturing capability, film materials and new manufacturing patients use equipment or exercise develop new functional materials, and methods for wearable technology; during rehabilitation. accelerate the translation of the science improving the mass production of carbon of functional materials through to nanotube materials; and advanced application have received a £10 million manufacturing of nanoparticles for CRUK upgrade investment from EPSRC. healthcare applications. EPSRC is deepening its strategic partnership with Cancer Research £40 million for synthetic £10 million for Internet UK (CRUK) through new co-funded multidisciplinary research projects biology research of Things research hub to improve our understanding of EPSRC is co-investing £40 million in The EPSRC-led Research Councils UK cancer, and boost innovation in cancer synthetic biology research across the UK. Digital Economy programme is investing diagnosis and treatment. £10 million in a new research hub to From materials used for advanced The new partnership increases the explore the interdisciplinary challenges manufacturing to developing new amount of joint EPSRC/CRUK funding around security, privacy and in the antibiotics and better tests for diseases, the for collaborative research over Internet of Things (IoT), and to translate investment is in one of the most promising five years. research findings into commercial . areas of modern science. The programme is a collaboration between Accelerating impact A total of £32 million will go towards three EPSRC, the Digital Economy Unit, Innovate Synthetic Biology Centres at the University EPSRC is investing a further UK, the Digital Catapult, and the Future of Edinburgh, the £30 million in Impact Acceleration Cities Catapult and is led by several and the University of Warwick. Accounts, which have been awarded leading universities. to 17 universities across the UK. An additional £8 million has been awarded to research partnerships across the UK £4.5 million for water, Impact Acceleration Accounts to help create the DNA starting blocks help speed up the contribution energy, food nexus required for synthetic biology applications. that scientists make towards new EPSRC is investing £4.5 million in innovation, successful businesses The investment comes from EPSRC, the interdisciplinary research involving and the economic returns that benefit Biotechnology and Biological Sciences 19 university groups and partners to help UK PLC. They also make it easier for Research Council (BBSRC), the Medical tackle the interlinked challenges facing scientists to develop their and to Research Council (MRC) and capital the UK’s water, energy and food security – collaborate with industry. investment from the UK Government. known as the water-energy-food nexus.

PIONEER 15 Summer 2015 5 EPSRC in numbers

£280 billion: The case studies featured in the REF were drawn from around 50 higher education , showcasing the The estimated contribution to the UK’s Gross Value Added impact of engineering research in all its forms. Together, (GVA) by engineering-related sectors in 2011, equivalent to they provide comprehensive of the economic and 20 per cent of the UK’s total GVA. social impact of UK engineering research over the last 20 The findings were made in an independent report on the years. One third of the case studies refer to increases in economic impact of engineering in the UK compiled by the productivity and competitiveness, citing research that has led Technopolis group and commissioned by EPSRC and the to new processes offering efficiency gains and cost savings. Royal Academy of Engineering. Similarly, REF demonstrates the impact arising from the The report estimated that engineering-related sectors UK research base and, in particular, from engineering and exported goods and services valued at around £239 physical sciences. EPSRC’s analysis of the REF case studies billion in 2011, some 48 per cent of the total value of within the engineering and physical sciences panel shows: exports for that year. It also flagged up the importance of • Over 85 per cent of case studies involved EPSRC-funded engineering research to key sectors including aerospace, research and/or researchers, and significant numbers pharmaceuticals, software and computing. of the studies are relevant to key UK sectors such as In addition, the report highlighted the role played by manufacturing, aerospace and defence, and healthcare the high concentrations of graduate engineers across • The studies cite over £1 billion of EPSRC funding – coupled the sectors, and the ability of engineering facilities and with a similar level of funding from sources such as businesses to attract substantial high-value, high-tech government, the EU and industry – demonstrating the high inward investment from around the world. levels of additional investment EPSRC support can attract The report was given privileged access to over 500 • EPSRC investments are associated with over £60 billion individual case studies from the Research Excellence of economic activity such as sales revenue and with over Framework (REF), the new system for assessing the £16 billion of cost savings in the public and private sectors of research in UK higher education institutions. • EPSRC investments are associated with the creation The 2014 REF was conducted jointly by the Higher of 400 new spin out businesses, employing over 50,000 Education Funding Council for England (HEFCE), the people and contributing £4 billion to the economy in Scottish Funding Council (SFC), the Higher Education terms of revenue Funding Council for Wales (HEFCW) and the Department for and Learning, Northern Ireland (DEL). Search engine: Research Excellence Framework £0.5 billion: 85 years:

Potential National Health Service savings through simple The duration of an hourly weather forecast predicting changes in purchasing practice using Artificial extreme UK conditions across the UK developed techniques developed by EPSRC-supported teams at by EPSRC-supported researchers at the universities of the University of Reading and Goldsmiths, University Bath and Exeter. of London. The project aims to help scientists and engineers Working with @UK PLC, the team, led by Professor understand how building designs react to different Mark Bishop and Dr Sebastian Danicic at Goldsmiths, weather conditions. developed ground-breaking SpendInsight software that Predicated weather conditions will be forecast until pinpoints potential savings by combining and mining 2100, representing typical weather and events such as purchasing data across systems and formats. lightning strikes, rain, flooding and tornadoes. The software was used in an analysis for the National These will be tested on more than 1,200 building Audit Office, which showed that the NHS could save over designs to establish how external temperature, wind and £0.5 billion in consumables expenditure through simple sun cause issues for people living inside, such as over changes to purchasing practice. One Trust has already demand on heating and air decreases. saved £320,000. Search engine: Spendinsight Search engine: Bath 85 years

PIONEER 15 Summer 2015 6 1st: How I spend my time Annette Bramley, Lead, EPSRC Healthcare The ranking given to Professor Technologies team Dame Wendy Hall in Computer Weekly magazine’s 25 Most Influential Women in UK IT list. Working with my team Working with charities, Dame Wendy is professor of 30% 20% on calls for research proposals. business and government. I spend computer science and Director It’s my team’s job to have its finger a lot of time talking with business, of the EPSRC Centre for Doctoral on the pulse of the latest research. charities and other potential partners, Training in Web Science Innovation We also work hard to ensure we to understand their challenges, and at the University of Southampton. target investments in areas most to illustrate to them how research in She is a founding director, with needed across the UK – by the engineering and the physical sciences Tim Berners-Lee, Nigel Shadbolt NHS, for example. To this end, we could help. I also identify opportunities and Daniel J Weitzner, of the Web invite academics to submit research for us to work together, and for them to Science Research Initiative, a proposals in areas identified as work with the researchers we support, long-term research collaboration strategically important – such as ensuring the research we invest in between Southampton and MIT. antimicrobial resistance and sensing is relevant and can be taken up in Search engine: Wendy Hall systems for healthcare. We do this healthcare applications. through ‘calls’ announced on our web site, social media and elsewhere. 20% Internal networking and 90%: Because the research landscape shifts management. My team spend a lot of over time our investment strategy has time on the road, so it’s important we The percentage of UK researchers to evolve with it. The conclusions from take time to share the knowledge we’ve across all disciplines who use a recent review we conducted with picked up. Healthcare Technologies research software in their work. academics and other partners will steer span EPSRC’s remit – from biochemists our investments for the next few years. Today there are very few science developing new wound dressings, to areas left which do not rely on IT In addition to the vital research we mathematical modellers predicting the and thus software for the majority of target through calls, we invest in great spread of disease. We work closely with their research. research ideas through individual colleagues across EPSRC, such as in the grant proposals from academics. This Manufacturing and ICT teams, sharing To ensure consistency and remains a core aspect of what we do. knowledge and looking at opportunities. , in 2010 EPSRC It’s also important for me to spend time invested in the creation of the developing the individuals within my Managing our investment Software Sustainability Institute 20% team, so they can work well as a team portfolio. EPSRC invests a significant (SSI) which provides resources to together and build their careers. support all engineering and physical proportion of its budget in healthcare science researchers, helping them technologies – from regenerative medicine to robotic surgery. generate ‘better research with 10% Other UK Research Councils better software’. To this end the SSI We seek peer review advice on every and Innovate UK. It’s important for has published over 70 guides and research proposal we receive. It’s the Research Councils and funding top tips on everything related to EPSRC’s job to manage this process, organisations like Innovate UK to software and research. and my responsibility to make funding work together, particularly in a The SSI has conducted pioneering decisions for healthcare technologies multidisciplinary applied subject like work to understand the research based on peer review advice. Excellence Healthcare Technologies. We’ve got a software community and to is the primary criterion, and the track record of working together on develop the resources, training highest priority proposals are funded. programmes of research and training and best practices that will Making funding decisions is a huge like the UK Regenerative Medicine allow this community to conduct responsibility, and I’m conscious of the Platform and EPSRC Centres for better research. passion and effort that academics put in Doctoral Training; and some of my when preparing an application. Gregory Wilson, Executive Director time is spent managing these. We of the international Software My team spend a lot of time visiting share ideas about future priorities and Carpentry Foundation, says: “We university groups whose research we calls and discuss the peer review and routinely point to the SSI as a model have invested in. By understanding their funding of multidisciplinary proposals that others should imitate.” , needs and concerns, we can that cross research council boundaries. get the best out of our investments and We’re all based in Swindon so it’s easy Search engine: Software develop ideas for the future. to meet up for coffee and talk shop. Sustainability Institute

PIONEER 15 Summer 2015 7 THINGS WE’VE LEARNED Natural language EPSRC-supported computer scientists at To find out more, type the keywords into your Heriot-Watt University and UCL (University favourite search engine. College London) are working with the Met Office to develop a technology that translates vast and complex data, such as weather information, and turns it into an easily read, ‘naturally’ written prose, as if written by a human. Search engine: Weather Crop updates mimic prose EPSRC-supported researchers at the University of Edinburgh have discovered Honed bones how communities of beneficial bacteria form a waterproof EPSRC-supported research coating on the roots of plants. at The University of This helps protect the plants from Manchester into disorders microbes that could potentially such as arthritis has led cause disease. to new x-ray software which automatically outlines bones Search engine: – saving thousands of hours of Edinburgh manual work. bacteria crops The research makes it possible to automatically pick out the shapes of bones in the images, rather than relying on individual researchers. Search engine: Software automatically bones Insects inspire hearing aid An insect-inspired microphone that can tackle Breast cancer predictor the problem of locating sounds, as well as eliminate background noise, could chart the future of modern-day Research at London’s Institute of Cancer hearing aid systems. Research, co-supported by EPSRC, has led to the development of a new test which can predict the The research, by scientists from the University of Strathclyde, survival chances of women with breast cancer the Medical Research Council (MRC) and Glasgow Royal by analysing computerised images of ‘hotspots’ Infirmary, was funded by EPSRC and will test an innovative where there has been a fierce immune reaction design using a miniature directional microphone – similar to to a tumour. The analysis is made possible the ear of an insect. through the use of statistical software previously Search engine: Insect-inspired waves microphone used in criminology studies of crime hotspots. Search engine: Immune ‘hotspots’ Sat-nav savvy Grant Ferguson, 17, from East Dunbarton, has become the first person to pass a new- UK driving test, which includes following directions on a sat-nav. Search engine: Grant Ferguson, 17

PIONEER 15 Summer 2015 8 Quantum Braking news A new flywheel-based regenerative wasp braking system has shown it can An EPSRC- reduce the carbon footprint of rail supported team travel on Britain’s diesel-powered from Glasgow trains, and can potentially increase University have capacity on crowded lines. harnessed the strange The system was power of quantum co-developed by mechanics to create a Artemis Intelligent digital image using fewer than Power, a company one photon per pixel. Conventional formed to digital cameras sample around 100,000 commercialise photons per pixel to make an image. The EPSRC-supported team used a technique known as quantum research at ghost imaging to create an image of a wasp the University of wing using just 50,000 particles of light. Edinburgh; Ricardo; and Search engine: Wasp wing quantum rail technology company Bombardier Transportation. Search engine: Regenerative Predicting braking Artemis harbour waves University of East Anglia researchers have developed sophisticated computerised mathematical modelling techniques to predict 3D-printed nerves the behaviour of harbour waves. The EPSRC- Scientists at the University of Sheffield have succeeded in using a supported work has enabled coastal engineers 3D-printed device to help nerves damaged in traumatic incidents to design and repair sea walls, and has been repair themselves. applied to a number of industrial projects, working The device, called a nerve guidance conduit, is a framework of tiny tubes with industrial partners. which guide the damaged nerve ends towards each other so that they can repair naturally. Patients with nerve injuries can suffer complete Search engine: UEA loss of sensation in the damaged area, which can be EPSRC sea wall extremely debilitating. The EPSRC-supported team used the device to repair nerve damage in animal models and say the method could help treat many types of traumatic injury. Search engine: Sheffield 3D nerve

Rolling road A new ‘rolling road’ installed at the University of Bath will allow researchers to accurately analyse fuel efficiency and vehicle emissions. The road, known as a dynamometer, will aid work carried out at the university’s Centre for Low Emission Vehicle Research (CLEVeR). EPSRC has invested £1.8 million in equipment funding for CLEVeR, with the University of Bath contributing £600,000. CLEVeR will address many of the future research challenges associated with low and ultra-low carbon vehicles. Search engine: Bath clever rolling

PIONEER 15 Summer 2015 9 THINGS WE’VE LEARNED Patents up Alternating The number of patents filed at the antibiotics European Patent Office (EPO) by UK companies rose by 4.8 per cent in An international research team, supported 2014 to 6,823, a sign of sustained by EPSRC and led by Professor Robert investment in research and Beardmore at the University of Exeter, development activity according to the have shown that using alternating doses of Intellectual Property firm, Withers antibiotics might offer effective treatment & Rogers. The increase is above the against bacterial infection. 1.2 per cent average across the 38 EPO Crucially, alternating doses also reduces member states, but falls behind China and the risk of the bacteria becoming resistant the US, which respectively increased by 18.2 to antibiotics, and so helps to maintain the per cent and 6.8 per cent over 2013 figures. long-term effectiveness of the drugs. Search engine: EPO Withers 4.8 Search engine: Alternating antibiotics

Anti-glare Graphene lightbulb coatings EPSRC-supported researchers A graphene lightbulb with lower at Loughborough University energy emissions, longer lifetime have developed a multi-layer and lower manufacturing costs anti-reflection coating for glass than for conventional bulbs surfaces, which reduces the sun’s has been developed through reflection from photovoltaic panels research at The University while at the same time improving of Manchester’s National their efficiency. Graphene Institute, in which Search engine: Loughborough EPSRC has co-invested over anti-reflection £60 million. A spin out company, Graphene Lighting PLC, has been formed to produce the lightbulb. Two-dimensional graphene is the strongest, most conductive material known to man, and was first isolated by EPSRC-supported researchers in 2004. Search engine: Graphene lightbulb

Nanoneedles for self-repair Scientists have developed tiny nanoneedles that have successfully prompted parts of the body to generate new blood vessels, in a trial in mice. The international research team, co-led by Professor Molly Stevens, from , and Houston Methodist Research Institute in the USA, hope their nanoneedle technique, which delivers nucleic acids (our genetic building blocks) to a specific area, could ultimately help damaged organs and nerves to repair themselves and help transplanted organs to thrive. Search engine: Imperial nanoneedles

PIONEER 15 Summer 2015 10 Stitch and chips Researchers at Nottingham Trent University have developed a way to embed clothes with tiny radio-frequency identification (RFID) data chips which cannot be seen in situ by the naked eye. The chips are embedded into yarns which are then woven to make fabric for clothing. The chips can contain all the information which is usually communicated via barcode. The patent-protected technology could lead to enhanced security at retail outlets, generating efficiencies in manufacturing and stocktaking, and allowing for clothes donated to to be tracked around the world. Measuring one millimetre by 0.5 millimetre in size, when bought in bulk the chips can cost only a few pence each. The research was funded by the EPSRC-led RCUK Digital Economy programme. Search engine: Invisible chips Nottingham Designs for life Research by EPSRC-supported Flight plans researchers at the University of EPSRC has invested £2.8 Salford suggests that million in a project to find well-designed ways to address the UK’s airport classrooms boost congestion without relying solely on the academic new airport building and expansion. performance of Led by a team at Lancaster University, the work will primary school create new algorithms and develop computer models based children. on huge quantities of data from individual airport and airline Search engine: operations, air traffic management systems, airport authorities, civil EPSRC Salford classrooms aviation authorities, airlines and the travelling public. Search engine: EPSRC Lancaster £2.8 million Doubling data speeds UCL (University College London) researchers supported by EPSRC have demonstrated a new way to process fibre optic signals which could double the distance at which data travels error-free through transatlantic sub- marine cables. Search engine: Fibre optic UCL transatlantic

Twisted light boosts net speed Scientists at the universities of Bristol and Dundee are exploring a new way of transmitting data using ‘twisted’ light beams. If successful, the technology will boost internet speed. Search engine: Drinkwater twisted light

PIONEER 15 Summer 2015 11 PEOPLE Pick of the crop Kerry O’Donnelly Weaver, a student at the EPSRC Centre for Doctoral Training in Chemical Biology at Imperial College London, has been named by the Royal Society of Chemistry (RSC) as one of its 175 Faces of Chemistry, an initiative launched to mark the RSC’s 175th anniversary celebrations. Kerry (pictured) shares top billing with luminaries such as Kevlar inventor Stephanie Kwolek; green chemistry pioneer Professor Sir Martyn Poliakoff; Marie Curie, who was the first person to be awarded the Nobel Prize in two different disciplines; and Alfred Nobel himself. Together with fellow CDT student Angela de Manzano, Kerry created FungiAlert, an award- winning device for the early detection of plant disease, and also formed a company to bring the PEOPLE research to market. Kerry says: “We wanted to design a product that would help to increase food production, focusing our on technology to help farmers reduce crop losses. If global crop losses were reduced by just one per cent, 24 million people would get to eat.” The low-cost device is inserted into the soil and alerts the user to the risk of fungal spores before they infect the crop. “You can look at it as a smoke alarm for farmers – it alerts you to the problem before it destroys everything,” says Kerry. “The development of FungiAlert has been an intense and steep learning curve, but this has only added to the enjoyment of running the company. We have truly loved being able to drive our project from idea and product development, to now having the opportunity to commercialise our invention.” Kerry and Angela were awarded a prize of £20,000 as well as entrepreneurial training and support from Imperial Innovations, an organisation which creates, builds and invests in pioneering technologies developed from academic research. Search engine: FungiAlert Kerry

PIONEER 15 Summer 2015 12 Thinking small Professors Miles Padgett and Lee Cronin, from the University of Glasgow, have joined forces once again to design, build, and test a new type of high resolution 3D printer system – capable of creating complex shapes at microscopic levels. With investment from EPSRC and the Royal Society, the team have developed a low cost, flexible and modular system combining the Padgett Group’s expertise in optics with the Cronin Group’s multi-faceted complex chemical systems research. The result is a manufacturing system that uses stereo-lithography ‘light printing’ to rapidly build low-cost 3D laboratory devices and systems with micro-scale features. Professor Cronin says: “3D printing is used widely in manufacturing industries, but has recently been taken up as a research tool. Commercially available 3D printers have already been used to cheaply fabricate devices with sub-millimetre features. However, as a research tool they can lack the flexibility needed in research laboratories. The teams are exploiting the innovation to develop 3D fluidic “Our printer can print intricate geometries and allows entire, chemical laboratories for drug discovery and cell engineering. large-scale 3D devices to be fabricated without any intermediate For more on 3D printing/Additive Manufacturing, turn to page 18. processing steps and allow large area objects to be stitched together like sewing pieces of material.” Search engine: Padgett Cronin 3D

Well equipped Crack shot Adrian Cox, from the University of Dr Katherine Tant (pictured), an Southampton, explains the thinking behind EPSRC-supported researcher at a new EPSRC-led equipment-sharing the University of Strathclyde, has initiative that gives all researchers access developed a system that uses sound waves to spot potentially to the vital kit they need for their work. dangerous cracks in pipes, aircraft engines and nuclear Adrian writes: Scientific equipment has always been an power plants while ensuring they operate reliably and without important requirement for many researchers. To make it easier compromising their integrity. The system also has potential for them to find the equipment they need, EPSRC is co-investing applications in medical imaging and seismology. in a new equipment.data web portal. Search engine: Tant Strathclyde cracks As project manager, I have been working with a number of UK universities, supported by Research Councils UK (RCUK), to build a comprehensive open source web site that harmonises the equipment databases of individual institutions, creating a single She said it national equipment sharing portal. The site uses a relatively simple piece of programming “A lack of new preservation technology that provides a ‘shop window’ for UK higher methods could be putting the education equipment and facilities. Not only does it improve accessibility, it also encourages conversations with the aim of future survival of many important stimulating greater collaboration in the sector. artefacts in jeopardy.” This has resulted in over 40 institutions now EPSRC-supported scientist, Zarah contributing with many more in the process of joining. There are Walsh, whose team have developed a safer, greener material now over 10,500 items of research equipment on the database. for conserving waterlogged wooden artefacts, such as those The project’s success has already been recognised in a new recovered from Henry VIII’s ship Mary Rose, which could report by Universities UK and is moving into a new phase, jointly preserve important pieces of our for future generations. funded by EPSRC and the Joint Information Systems Committee. Search engine: Zarah Walsh artefacts Search engine: Equipment data ac

PIONEER 15 Summer 2015 13 PEOPLE Sweet success Twenty years of research by Professor impossible to source. Professor Wong plentiful. The real benefit is that the Luet Wong at the Department of turned to the orange tree for a solution. end product is completely natural.” Chemistry, University of Oxford, is about Oranges produce valencene, a readily The EPSRC-supported research to bear its first in the form of a obtained citrus extract very similar is being taken forward by spin out new and natural way to produce the to nootkatone. However, while it’s company, Oxford Biotrans. elusive nootkatone molecule – a tiny relatively easy to convert valencene compound with huge commercial clout. The company has joined forces with into nootkatone, existing methods use De Monchy Aromatics, a UK-based Produced in miniscule amounts by heavy metal catalysts and peroxides supplier of aroma chemicals and plants such as grapefruit, nootkatone – toxic chemicals that require careful essential oils, to manufacture and is a highly sought-after natural disposal. Professor Wong’s team market nootkatone on a commercial compound used in a host of products used the techniques of synthetic scale. Crucially, the product complies – from citrus-based soft drinks and biology to develop a natural enzymatic with strict EU and Food Standards confectionery to perfumes. The global process to convert valencene into Agency guidelines. market for flavours and fragrances is nootkatone, devising a technology worth over US$22 billion. that could be used to make a host of This is just the start of the story. established products and potential A pipeline of flavour/fragrance The trouble is, nootkatone, which gives products is under development, and grapefruit its aroma and flavour, is new ones through a sustainable, biological process. Oxford Biotrans’ technology has the created by some of the most complex potential to be used in the production reactions in biology. It takes around Professor Wong says: “Our technique of pharmaceuticals, agrochemicals 400,000kg of grapefruit to produce currently uses our enzymes to and other speciality chemicals. It 1kg of nootkatone, which puts it transform commonly available natural could even open the door to new in the same price bracket as extracts into our target flavour and fragrances, pharmaceuticals and beluga caviar. fragrance compounds. natural insect repellents. What’s more, grapefruit “The process requires little energy and About Nootkatone supply is affected generates almost no waste in contrast by disease; and in to conventional chemical processes. Nootkatone is a citrus ingredient hurricane years Valencene is also available from characteristically associated with nootkatone can be multiple sources; and supply grapefruit. It has two main uses or is always potential uses: As a flavour and fragrance ingredient Nootkatone has a rare characteristic that enables it to last on skin and cloth for an extended period of time, making it highly valuable for personal care products. For insect control Nootkatone is a type of terpene – highly-aromatic chemicals which deter animals that might eat the plant, and act as natural insect repellents. It is effective against a range of insect pests including ticks, bed bugs and mosquitoes. Search engine: Nootkatone Wong

PIONEER 15 Summer 2015 14 Professor Philip Nelson, Chief Executive Picture courtesy University of Southampton that fits on to the end of an of EPSRC, has been elected as the ordinary domestic tap, hose or next Chair of the Research Councils industrial nozzle. UK (RCUK) Executive Group. Professor Nelson will take on the role from Described by One Show presenter 1 October 2015. Matt Baker as “unbelievable Search engine: Nelson RCUK chair technology”, StarStream®, invented by Leighton (pictured An award-winning new dental bone left with the device) and his graft material is to bring a shot of colleague Professor Peter Birkin, innovation to the field of advanced dental can enhance the cleaning power surgery. The team behind the invention – of a gentle stream of water Dr Niall Kent, from the EPSRC Frontier from a household tap by up to Engineering Centre for Nature Inspired 1,000 times. Numerous potential Engineering at UCL (University College applications include cleaning London), and Dr Alessia D’Onofrio – Bubble gun products for hospital , dentistry, claim the material significantly improves Professor Tim Leighton, from the food preparation, manufacturing and the on existing bone substitutes. University of Southampton, has made power industries. After winning first prize in a competition his debut on BBC TV’s The One Show. The fundamental research for run by the Royal Academy of StarStream®, which will be produced Interviewed by Dr Michael Mosley, Engineering’s Enterprise Hub, the team Professor Leighton demonstrated commercially by Ultrawave Ltd, was hope to take the dental graft material, a close-to-production model of an supported by EPSRC; an early prototype called Aerograft, to market. extraordinary ultrasonic cleaning tool featured in Pioneer 7 in 2012. Search engine: Aerograft resembling the nozzle of a petrol pump Search engine: StarStream Professor Sir David Payne, Director of the EPSRC Optoelectronics Research Centre at the University of Southampton, Seeing sound He said it has been listed in Debrett’s top 500 most influential people in Britain. Ever since musician Professor Eduardo “I can envisage this Search engine: David Payne Miranda met a patient with Locked-in Syndrome 11 years ago, he has been on a developing into a Helene Jones, a student at the mission to create a way for the paralyzed routine tool that EPSRC Centre for Doctoral Training in to make music. Advanced Composites for Innovation The EPSRC-supported Plymouth your local surgery and Science at the University of Bristol, University researcher’s can use when you has designed and developed a hand- latest invention is the held laminating tool, known as the Brain Computer Music go for your annual Dibber, for use in the layup of advanced Interface which allows check-up.” composite components. The tool could people to create music be used by laminators to manufacture using just their eyes. UCL’s Professor Allen Goodship on composite materials in industries such EPSRC-supported research which, as aerospace. By connecting for the first time, has enabled electrodes to the Search engine: Dibber Helene detection of a genetic ‘brittle bone’ back of a person’s Two EPSRC-supported researchers, disease known as Osteogenesis head, the system Imperfecta by simply scanning a Dr Patrick Farrell from the University can tell where patient’s limbs. of Oxford, and Dr David Ham, they are looking from Imperial College London, are Working with the Royal National by monitoring brain co-recipients, with Marie Rognes and Orthopaedic Hospital, the team’s activity. Flashing icons Simon Funke, of the 2015 Wilkinson technique uses spatially offset representing different Prize, awarded every four years to Raman Spectroscopy, developed snippets of music appear outstanding contributions on screen and the user can then make at the Science and Technology in the field of numerical software. a selection, just by staring at one. In Facilities Council’s Central Laser The open source software is being real time, another musician plays an Facility, to shine a laser through the used by scientists in areas such as instrument according to the score skin to analyse the chemistry of the understanding the movement of generated from the user’s selections. underlying bone. Antarctic ice sheets. Search engine: Goodship brittle Search engine: Miranda music Search engine: Wilkinson Prize bone

PIONEER 15 Summer 2015 15 PEOPLE

Future build

Ester Coma-Bassas, Carbon Research Institute’s SOLCER perceived to be costly and difficult. an EPSRC-supported project, in partnership with SPECIFIC. We used affordable, off the shelf architect based at technologies available locally, and As the name suggests, Buildings as the Welsh School were able to integrate all systems into Power Stations is all about integrating of Architecture, one design, resulting in an energy and implementing energy systems describes her latest positive house. into buildings to optimise energy self- work on the ground-breaking SOLCER sufficiency while providing a comfortable The house, which will be monitored to energy positive house, the first in the environment for its occupants. assess its performance, is proof that it’s UK capable of exporting more energy to possible to produce low-cost, practical the National Grid than it consumes. The design of the house was a buildings that can generate, store and Ester (pictured) says: “My research big challenge. Instead of taking a release their own renewable energy.” traditional approach where design focuses on the of Buildings as Ester is funded by SPECIFIC through and are the most important Power Stations (BAPS), developed by the EPSRC and the Welsh Government- thing, I needed to focus on the SPECIFIC, an Innovation and Knowledge funded Sêr Cymru Solar project. building’s performance, while ensuring Centre in South Wales funded Partners include BASF, Tata Steel, mainly through major investments affordability and replicability within Pilkington and many Welsh SMEs – from EPSRC, Innovate UK and the the social housing sector. It was also enabling knowledge and skills transfer Welsh Government. important to develop new design, between local industries. modelling and assessment software The project was led by Professor Phil In 2015 Ester was named Young Jones, from Cardiff University, and for architects to use, as most are unfamiliar with ‘performance-driven’ Achiever of the Year at the Construction the house was designed and built by Excellence in Wales Awards. his team from the Welsh School of design and systems optimisation. Architecture, as part of the Wales Low Building low carbon homes is generally Search engine: SOLCER House

PIONEER 15 Summer 2015 16 Harry Bhadeshia, professor of (pictured second left), a doctoral student metallurgy at the University of at the EPSRC-supported Cambridge Cambridge, has been knighted in the Centre for Smart Infrastructure and 2015 Queen’s Birthday List. Construction (CSIC), has won a clutch In a prolific career, supported of awards since its launch in 2013, throughout by EPSRC, Professor including the Technical Excellence and Sir Harry has made huge scientific Product Innovation Awards at the 2015 contributions towards the invention of Ground Engineering Awards. new iron alloys. Most recently, Heba received the Search engine: Bhadeshia REF Innovation prize at the Constructing armour Excellence in London and the South East Professor Dimitrios Nikolopoulos, Utterly fabulous awards, where the judges described from Queen’s University Belfast, UtterBerry as a “a quantum step in UtterBerry, a wireless sensor for civil is leading a project to create measurement sensors”. engineering instrumentation and new computer software that will monitoring developed by Heba Bevan Search engine: Utterberry dramatically increase the ability of supercomputers to process masses of data at higher speeds than ever. New wave radio Professor Nikolopoulos says: “The Leo Laughlin, a wi-fi access point, allowing more users and new software, developed with doctoral student at higher data rates. University of Manchester researchers the EPSRC Centre for and a team from the Science and For mobile/cellular systems, capacity and Doctoral Training in Technology Facilities Council’s data rates would be increased, or network Communications at Daresbury Laboratory, means that operators would be able to provide the the University of Bristol, has co-led the complex computing simulations which same total network capacity with fewer development of technology that enables would take thousands of years on a base station sites, leading to benefits in the a radio device to transmit and receive on desktop computer will be completed cost and environmental impact of running the same channel at the same time. in a matter of hours. the network. It could also allow for global Because only one channel is required roaming on 4G networks. “This research has the potential to for two-way communication, the device give us insights into how to combat uses half as much of the radio spectrum Leo says: “Until now there has been some of the biggest issues facing compared to the current technology. a fundamental unsolved problem with humanity at the moment.” Part of the to 5G mobile, the radio communication. Search engine: SERT QUB research is also relevant to the design of “Since the radio spectrum is a limited the radio circuitry in current 3G and 4G Dr Ali Salehi-Reyhani, a former resource, and with network operators cellular mobile devices. EPSRC-supported doctoral student paying billions of pounds to access the at Imperial College London’s Institute Developed with MSc student Chunqing spectrum, solving this problem would of Chemical Biology Centre for Zhang, Professor Mark Beach, Dr Kevin bring us one step closer to the faster, Doctoral Training, and Dr Duncan Morris, and industrial mentor, Dr John cheaper and greener devices of our Casey, from the Institute of Chemical Haine at u-blox, the prototype design connected future.” Biology, have developed a handheld, could offer a range of benefits. In wi-fi disposable research tool that systems it would double the capacity of a Search engine: Leo duplex instantly analyses mixtures such as groundwater or blood. For many researchers, the device Ground effects could make the need to transport Dr Mike Brown, from the University of Currently, the main foundation solutions samples back to the lab a thing of Dundee, is leading a research project being considered for offshore wind the past as analysis could take place to determine whether cheaper, more installations are driven piles, large in situ. environmentally friendly, and more effective monopiles or concrete gravity-based To bring the tool to market, the foundations can be developed for the structures. Driving of piles in large numbers team set up a spin out company, offshore renewables industry. offshore causes concerns over plant anywhereHPLC, which has gone on to The EPSRC-supported project is looking availability and impact on marine mammals. win awards, including the first prize at the use of screw piles for offshore Screw piles are potentially very attractive of €20,000 at Climate-KIC UK’s Big installations. Screw piles are foundations as a lower cost and more environmentally Idea Bootcamp. Dr Reyhani is now a screwed into the ground and are widely friendly option. postdoctoral researcher at Imperial. used onshore, one example being to support Search engine: anywhereHPLC motorway signs and gantries. Search engine: Dundee screw piles

PIONEER 15 Summer 2015 17 Additive Manufacturing Special Report The layer game Additive Manufacturing (AM) has come a long way in just over two decades, and is graduating into mainstream manufacturing. EPSRC is right at the heart of this revolution.

Additive Manufacturing is known drugs and even food – there is now deposition modeling, laser sintering by many names. Depending on the research into printing processed and 3D printing. Between them, context, it is also referred to as Rapid foods, as well as personalised high they set the blueprint for much that Prototyping and 3D printing – the value products such as jewellery. followed. In the UK the vanguard of media-friendly technology that has AM can also enable companies this technology was led mostly by seen the arrival of 3D chocolate to reduce key business metrics – EPSRC-supported engineers at the printers and other consumer-based lead times, production times and start of stellar academic careers, products. The common denominator material cost. The conditional tense among them Chris Sutcliffe, Phill to all these variants is the basic is important; AM cannot match Dickens, Bill O’Neill, Bernard Hon process – that of adding material to conventional processes such as and David Wimpenny. make a product, layer by layer. milling for making particular, high Over 20 years later, many of Perhaps the most important report volume parts with micron-level these early pioneers continue to on UK manufacturing in recent years, tolerances – yet. drive the R&D agenda in Additive the UK Government’s The Future But the AM R&D landscape is shifting Manufacturing; they have also of Manufacturing Foresight Report, fast, and the global momentum is nurtured the brightest new talent, cites Additive Manufacturing (AM), as accelerating, driven by breakthrough including Professor Richard Hague, a key enabling technology for high innovations such as new processes Professor Russ Harris and Professor value manufacturing. It says AM’s for rapid volume manufacture Neil Hopkinson, who all started benefits, such as smarter supply and exciting advances in new AM their careers as EPSRC-supported chains, digital manufacturing flexibility materials. In 2014, the market for PhD students. All now lead their and design freedoms, will dramatically all Additive Manufactured products own departments. change the way components are and services worldwide grew at Closing the circle, in 2015 Phill designed, developed, manufactured a compound annual growth rate Dickens was awarded an EPSRC- and supplied. The report mentions of 35 per cent to US$4.1 billion, funded Foresight Fellowship, a role AM no less than 35 times. AM is according to Wohlers Report 2015. designed to link work across the also identified by Innovate UK, the Making most of the UK research entire UK Additive Manufacturing government’s innovation agency, in its possible is EPSRC, which has invested landscape and to help make the High Value Manufacturing Strategy as in Additive Manufacturing research technology more competitive one of the key competencies necessary and training since the early 1990s, with conventional manufacturing for future manufacturing success. It is when the technology was emerging as processes. He recently co-founded not a technology to ignore. a new research discipline. consultancy firm, Added Scientific, with colleagues from The University of Why is this technology so important? In the early days, there were several Firstly it is cross-sectoral, with distinct but related technologies, Nottingham, including his former PhD applications from aerospace and each with their own benefits and student, Richard Hague (see page 28). automotive parts, to medical devices, limitations: stereolithography, fused (Continued on page 21)

PIONEER 15 Summer 2015 18 The layer game

Manually actuated prosthetic hand created via laser sintering.

PIONEER 15 Summer 2015 19 Doctoral student Amanda Hüsler operating a contact angle measurement system.

PIONEER 15 Summer 2015 20 (Continued from page 18) commercialisation of the technologies, such as low speed and product size EPSRC investments limitations. This report reviews some Additive UK academic research in AM is of the primary AM research fields. Manufacturing thriving, and its applications are Turn up the volume flourishing. Dr Karen Brakspear, The most conventional Additive Additive Manufacturing is radically EPSRC’s Additive Manufacturing Manufacturing technique is laser different from conventional portfolio manager, estimates that, sintering, a layer by layer powder- manufacturing processes such of the UK universities with Additive based process. as machining, casting, forging Manufacturing research labs, about and moulding. It forms objects by Laser sintering is mainly used to 50 per cent have received investments building up matter, layer by layer, create very high quality nylon parts for from EPSRC – including dedicated rather than removing it. A high use in industries such as aerospace. Centres for Innovative Manufacturing energy source, usually from a laser, However, it is slow, and unsuitable for and Centres for Doctoral Training. is used to melt or fuse powders. She says: “EPSRC is investing in large production runs, causing AM major research programmes at pioneer Professor Neil Hopkinson to The design of these components is developed using computer- 13 of these universities as well as remark: “Conventional laser sintering generated 3D models and digital smaller projects nationwide. It’s is like painting a room with a biro – it’s design data. also developing a new generation just not a good way to do it quickly.” of talented doctoral students, who In the early 2000s, together with Paired with computer-aided design will become the research leaders of his team at the EPSRC Innovative (CAD) software, this technique the future.” Manufacturing and Construction affords the creation of new types of object with unique material The breadth and depth of Additive Research Centre (IMCRC) at properties. Manufacturing research in the UK Loughborough University, Neil is nationwide. From laser-based Hopkinson and his team set about The fastest-growing areas for processes that improve post-process refining the process so that it could Additive Manufacturing include finishing of AM parts at Heriot-Watt be applied to large-scale component the medical and dental sectors, University in Edinburgh to polymer manufacture. What they came up where it is being used to create laser sintering research at Exeter with was a revolutionary Additive customised prosthetics, implants, University, engineers and increasingly Manufacturing technology, High Speed replacement tissues and intricate chemists and physicists are making Sintering (HSS), that is set to change body parts, including blood vessels. breakthroughs on a swathe of AM the way certain components are Hearing aids and medical implants processes all the time. created using AM. are already being customised Similar to laser sintering but based on rapidly for individual requirements Factor in the myriad ways in which and then produced by AM. EPSRC-supported researchers a print head and infrared system, HSS are using Additive Manufacturing is capable of producing high volume Additive Manufacturing has also techniques to bring their research production parts not possible using been embraced in the aerospace to fruition – from 3D-printed canine conventional laser sintering and can sector, where it is being used to prosthetics to AM-generated concrete thus be applied to rapid large-scale create low-weight, high strength panels for large-scale buildings (see component manufacture. components, among other applications. page 28) – and the nationwide picture The invention dates back to becomes particularly healthy. 2003, when Professor Hopkinson AM: the benefits AM is also changing fast. “There successfully applied for an is a continuing need for research EPSRC grant to investigate a new • Greater design freedom in Additive Manufacturing, both in manufacturing process. underpinning the knowledge gaps in Further EPSRC-funded projects • No tooling the current commercial exploitation followed, including one that • Production numbers can but also in the novel areas of new enabled the IMCRC team to create be low materials, new products, and new personalised footwear using • Fast response to orders processes,” says Dr Brakspear. “It is Additive Manufacturing. increasingly important as an enabling • Combine parts – reduce The next breakthrough came in 2011 tool for high value manufacturing – assembly when, supported by a grant from the such as in the aerospace, healthcare Higher Education Funding Council • Customised products and specialist industrial sectors.” for England (HEFCE), the team built • Makes it possible to Long-term and consistent EPSRC- a new High Speed Sintering test manufacture in new locations/ funded research is now helping machine from scratch. on site, reducing transport engineers to overcome some of the costs and carbon footprint significant hurdles for successful (Continued on page 23)

PIONEER 15 Summer 2015 21 A stainless steel dome structure created via Selective Laser Melting.

PIONEER 15 Summer 2015 22 (Continued from page 21) David Chapman, who is responsible AM goes large The machine was completely designed for developing Xaar’s AM business, Speed and physical size have been using off-the-shelf technology and says: “This is potentially industry- traditional limitations of Additive was subsequently patented by Neil changing as it will increasingly Manufacturing. But Professor Iain Hopkinson and Dr Helen Thomas. allow companies to provide products Todd, based at the University of on demand.” In the same year, Loughborough Sheffield’s Department of Materials University loaned the newly-built In 2015, EPSRC invested £1 million in Science and Engineering, working HSS machine to the University of a new project to enable the Sheffield with project partners Rolls-Royce Sheffield, which had the facilities and team to build a large High Speed and the Manufacturing Technology set up that would enable Professor Sintering machine capable of working Centre, has succeeded in fabricating Hopkinson, who also transferred to with a number of different materials. an unusually large component, a Sheffield, to prove to industry that The technology is being licensed to 1.5 meter-diameter titanium front the technology can compete with industrial machine manufacturers bearing housing for the Rolls-Royce traditional manufacturing techniques on a non-exclusive basis, and Trent XWB-97 engine, the power-plant and laser sintering. Loughborough University is actively for the Airbus A380. seeking new licensees, with new Work proceeded apace, supported The project, borne out of Professor machines expected on the market by investment from Innovate UK and Todd’s EPSRC-supported research, from 2017/18. with project partners including BAE marks the first time Additive Layer Systems, Cobham, British printing Professor Hopkinson says: “I believe Manufacturing has been used to group Xaar, Unilever and Sebastian that in 10 years’ time producing produce such a significant load- Conran Design. In just one year, volumes of over a million using Additive bearing component, rather than the Loughborough University, which Manufacturing will be commonplace.” conventional processes of casting holds the intellectual property to Head of Intellectual Property or forging. the technology, had signed its first Commercialisation at Loughborough Neil Mantle, Head of the Rolls-Royce licencing deal. University, Dr Joanne Whitaker, who Centre of Competence – Additive In 2015 the project team proved their has helped to drive the development Layer Manufacturing, says: “Without machine can build plastic parts up of HSS technology, says: “Credit the early support from EPSRC, Iain to three times larger and 100 times for this breakthrough must go Todd and his researchers at the faster than comparable Additive to Loughborough and Sheffield University of Sheffield and follow-on Manufacturing machines, and is universities themselves, as the support from Innovate UK and the capable of challenging conventional technology could not have been Manufacturing Technology Centre injection moulding for high volume developed so quickly or smoothly production parts. without their long-term collaboration.” (Continued on next page)

AM, business, and skills

What are the business challenges For example, the need to develop local production preventing AM applications from competence and maintain quality control over dispersed being adopted more quickly, or geographic locations may cancel out many of the more pervasively? Dr Tim Minshall, potential benefits. Director of Manufacturing Engineering There are also two AM skills-related issues. Firstly, Tripos (MET) at the Institute for Manufacturing, University of Cambridge, explains: the and diffusion of these technologies is resulting in the need for some changes to be made to It has been really interesting to observe the different university engineering curricula. ways in which UK companies in a variety of sectors – from aerospace to automotive to dentistry to jewellery The second category relates to the way in which the – have adopted Additive Manufacturing technologies high visibility of AM among the broader population has for use in rapid prototyping, rapid tooling, and the potential to increase engagement with science, direct manufacturing. technology and mathematics education at primary and secondary level schooling. AM technologies have the potential to be used in spare parts strategies for manufacturing firms. While there What does seem to be clear is that the wider adoption is a clear logic for applying AM to produce spare parts of AM technologies will require the development and on-demand and on-location, for example, on a ship, communication of fundamental data on AM materials in a combat zone, or at a remote mining location, this and production processes to give firms the confidence to could impact a manufacturing firm’s business model. use these technologies more readily.

PIONEER 15 Summer 2015 23 The Wire+ARC Additive Manufacturing Process utilises arc welding tools combined with wire feeding.

(Continued from page 23) Richard Hague and colleagues are dosages and drug implants using Additive Manufacturing to customised for individual patients. in Ansty, it would have taken a significantly longer time to develop create a range of multi-material, University of Nottingham bio-engineer the technology needed to create such multifunctional products. Professor Kevin Shakesheff, an challenging components.” Professor Hague says: “Conventionally, EPSRC RISE Leader, has already The significance of this project cannot Additive Manufacturing uses single co-developed 3D scaffolds that can be underestimated; it marks the materials, a polymer or a metal, which be injected into the body without the successful application of a ‘disruptive’ are fused together with a laser. You need for surgery, and which leave no technology in a highly regulated can create interwoven geometries but solvents or toxic by-products. He has industry where all components are they’re still passive. also demonstrated how the technology could be used to print human organs. tested to destruction, and where “Our research involves activating confidence in processes and part these materials and making them Professor Shakesheff says: “We know integrity must be absolute. functional. So, rather than make how to reprogram cells to become Later in 2015, one of the most a component, you make the whole stem cells; we have technologies such prominent names in aerospace, GE system. In the future this might mean as 3D printing and advanced materials Aviation, is introducing a fuel nozzle that, rather than print a part and that can build those cells into organ built using AM into its GE LEAP 56 assemble the electronics, the whole structures, and we understand a lot of engine. It took 15 years to develop, object could be built in one print.” the cell and tissue biology that allows test and approve. tissues to form and repair. This exciting research paves the way Multifunctional materials for a host of different ‘embedded’ “I can’t see any fundamental barrier that will stop future generations being Additive Manufacturing is a technology products including sensors, able to grow a personalised organ.” that is as much about materials batteries, solar cells, LED screens, science and chemistry as it is and antennae. They could also The importance of lasers engineering and machine building. revolutionise healthcare. The laser is a crucial part of many At The University of Nottingham, Working with the university’s School Additive Manufacturing processes, which hosts the EPSRC Centre for of Pharmacy, Professor Hague’s group providing a highly localised and Innovative Manufacturing in Additive is researching new mechanisms controllable source of heat that can Manufacturing, in partnership with combining Additive Manufacturing and be translated at high speeds; indeed Loughborough University, Professor drug delivery, including personalised metal powder-based AM processes

PIONEER 15 Summer 2015 24 almost exclusively use a laser to melt team are working with BAE Systems A National Strategy for Additive and fuse the powder. to improve the process and to develop Manufacturing Lasers also have an important role to additional parts and processes that The UK is amongst the global leaders in post-processing of AM parts, can be applied commercially. in both the development of knowledge both for shock peening (a process to AM and the UK economy and successful application of Additive increase the resistance of materials Manufacturing/3D printing technology, Until recently, less attention had been to surface-related failures) and for but there are gaps in the industrial focused on the non-technical side of machining/polishing; these aspects ecosystem that need to be addressed Additive Manufacturing. are both being investigated within the if the UK is to capture value from the EPSRC-funded Centre for Innovative Thanks to support from EPSRC, opportunities presented. Manufacturing in Laser-based Dr Tim Minshall and a team at To respond to these issues, a steering Production Processes (CIM-Laser), the Institute for Manufacturing at group of experts from industry, together with a focus on laser-powder the University of Cambridge have academia and government, including interaction fundamentals to improve researched the linkages between the Rolls-Royce, GKN Aerospace and process consistency. technical, economic and policy issues Innovate UK, is developing a new WAAM affecting the diffusion of Additive UK National Strategy for Additive Manufacturing technologies. Manufacturing, due to be published In addition to this work, CIM-Laser is in 2016, to help accelerate the using its research to fully understand “What’s particularly helpful is the support and openness of EPSRC- industrialisation of this radical new a remarkable new Wire+Arc Additive way of making things. Manufacturing (WAAM) technique, funded colleagues with deep developed by Professor Stewart knowledge of the technical aspects of Robin Wilson, Innovate UK’s Williams at Cranfield University, to Additive Manufacturing, coupled with Lead Technologist for High Value reduce variation in the process, and the strong engagement of industry Manufacturing, says: “The creation increase consistency and reliability. and policy partners,” says Dr Minshall. of a supporting infrastructure in the “With this support, we can do several UK is essential in order to provide Dr Filomeno Martina, a Research things. We’ll be able to examine the companies with the necessary Fellow in Additive Manufacturing at current and potential disruptions to design and process knowledge, Cranfield, who joined the academic business models resulting from the skills, materials data and risk staff after completing his PhD in AM at management information. the university, supervised by Stewart application of AM technologies in a Williams, says: “Wire+Arc is different wide range of sectors; we’ll have the “The steering group has enabled us from other AM processes in that it chance to support multidisciplinary to engage with a wide group of over utilises arc welding tools combined research that explores the impact of 150 stakeholders, to identify the key with wire feeding. AM technologies on the re-distribution barriers and enablers. of manufacturing activities; and (Continued on next page) “This enables much higher deposition we’ll be able to assist with the rates and potentially limitless part development of a national strategy size. In , we have been able to for Additive Manufacturing.” manufacture parts around three metres in length. “Thanks to low capital and material costs, this can be done in a much Right: Working with project cheaper way, too. Compared to partners Rolls-Royce and the machining from solid, WAAM is Manufacturing Technology typically 50 per cent to 60 per Centre, Professor Iain Todd cent cheaper.” succeeded in fabricating this 1.5 meter-diameter In a remarkable breakthrough, titanium front bearing Professor Williams’ Wire+Arc housing for the Rolls- Royce Trent XWB-97 process has already been used to engine, the power- make a 1.2 metre titanium part of plant for the Airbus an aircraft wing – one of the largest A380 (see page 23). metal parts produced using Additive Manufacturing. Designed by BAE Systems engineers, the component forms a main structural element of an aircraft wing structure. It took just 37 hours to build from a digital model. Previously this process would have taken weeks. The

PIONEER 15 Summer 2015 25 (Continued from previous page) Just as Phill Dickens and his Newcastle and Liverpool universities, “We can use this latest feedback to contemporaries helped pioneer the centre is training over 40 build the right kind of infrastructure Additive Manufacturing research in doctoral students in this diverse and support network that meet the the UK, a new generation of dynamic and multidisciplinary field. Each immediate needs of innovative UK young engineers have taken up the PhD project has a specific link to an manufacturers as they acquire these baton. To help ensure the continuous industrial partner. breakthrough production capabilities.” development of AM research, in Adam Thompson, a student at the The steering group is chaired by 2013 EPSRC launched the Centre centre, says: “As we progress into our Rolls-Royce’s Neil Mantle, and most of for Doctoral Training in Additive second year, we do so with the sense its members have a direct or indirect Manufacturing and 3D printing. Led that we are building an excellent base link to EPSRC, including Professor by The University of Nottingham, for our future careers and that we are Phill Dickens. in partnership with Loughborough, all part of the AM revolution.”

Additive manufacturing – a personal journey

Additive in the provision of more robust parts Richard along with colleagues, Manufacturing/3D for test of form and fit and even the Ricky Wildman, Ian Ashcroft and printing has advent of Rapid Tooling; utilising the Chris Tuck, began to explore its roots in the use of layer-by-layer technology to multi-faceted and multidisciplinary development of Rapid Prototyping produce tooling for injection moulding. projects in order to show the during the 1980s and 90s. My team, which included Richard importance of coupling design, RP as it was known, was considered Hague, an EPSRC-supported materials and process together a great step in the reduction of lead industrial CASE student, continued to with multifunctional structures. times for a number of products, research and develop the technology This allowed strategic partners and effectively allowing prototype parts at The University of Nottingham alliances to benefit from the entire and to be produced in a and started to show its potential to offering that AM was beginning matter of hours rather than weeks a range of sectors and industries to present as a manufacturing and months. through patents. solution for high value, custom and bespoke products. It was clear EPSRC was quick to invest in A new era: As the 2000s began, using that 3D printing was not just about blue-skies research in this new layer-by-layer techniques to produce the machines. technology. The potential benefits actual products became a logical were obvious, but the research next step. An explosion: From 2011, the was in its infancy, and commercial advent of 3D printing and the Research began into the use of prior exploitation was clearly a long way explosion of consumer 3D printing RP technologies as manufacturing down the road. Over the decades, systems has brought about a tools, with those skilled in the art EPSRC support has been constant, significant degree of interest in the beginning to realise the fundamental both for research and PhD training. field, but importantly, a significant design and product potential that amount of misinformation. Enabling technology: Worldwide, could be achieved. research groups throughout the To tackle this problem, Richard, During the 2000s new technology 90s began to explore the uses Ricky, Ian, Chris and myself came on stream with metallic of 3D printing technology. At formed a spin out company, Added systems becoming available. My that time this was principally: Scientific, to allow research research group was growing, and in stereolithography; fused deposition partners to cut through the hype the mid-2000s Richard took over as modeling; laser sintering and 3D and focus on what added benefits head as I became the Director of the printing – distinct technologies with EPSRC Innovative Manufacturing and they could realise from this exciting their own benefits and limitations. technology, whether their interest Development continued apace, Construction Research Centre and Associate Dean of Research. be in how to implement it or in with new software tools and the specifics such as new materials, continued improvement of materials Concentration: Recognising the move processes and design requirements. and processes, to enable Rapid to manufacturing as being one that Prototyping to be more relevant would massively expand the potential to customers. This was embodied application of AM and 3D Printing, Professor Phill Dickens

PIONEER 15 Summer 2015 26 EPSRC-supported Additive Manufacturing investments and 3D printing research projects (August 2015)

The EPSRC Centre for Innovative 3DP-RDM: The adoption of Additive Manufacturing in Additive Manufacturing is likely to lead Manufacturing, led by The University to dramatic transformations as £28m of Nottingham in partnership with companies simplify their supply chains Loughborough University and and adopt novel business models. Contributed by industry for industrial partners, is a nucleus The 3D Printing Enabled Re-distributed EPSRC-supported Additive of research activity focused on Manufacturing (3DP-RDM) network, led developing next-generation by the University of Cambridge, brings Manufacturing research multifunctional AM technology – together academic, industry and policy combining multiple materials and experts to explore interconnected projects functions for complex electrical, technological, commercial and policy optical and structural properties in a issues surrounding AM, including Foresight Fellowships: In 2013 the single manufacturing process. skills, standardisation, process control, UK Government published The Future recyclability and the protection of of Manufacturing Foresight Report intellectual property. which looked at the long-term picture for the UK manufacturing sector up 46 The EPSRC Centre for Doctoral to 2050, investigating global trends Training in Additive Manufacturing and drivers of change. The number of EPSRC and 3D Printing, led by The University Additive Manufacturing was identified investments in Additive of Nottingham, in partnership with as an underpinning technology that Loughborough, Newcastle and will enable developments in other Manufacturing-related Liverpool universities, is training over scientific areas and will cut across 40 doctoral students to become the research projects all sectors. EPSRC has funded two next generation of leaders, scientists Fellowships whose recipients will and engineers in this diverse and respond to the AM-related technology The EPSRC Centre for Innovative multidisciplinary field. challenges identified through Manufacturing in Laser- Each PhD project has a specific innovative research projects and key Based Production Processes, link to an industrial partner who agenda-setting activities. a collaboration between five can see the potential benefits of UK universities, is developing Additive Manufacturing technology to Design the Future: This initiative and refining new laser-based their business. explores adventurous new manufacturing techniques. approaches to engineering design Additive Manufacturing, which Novel Manufacturing through diverse feasibility projects. relies on enhanced laser efficiency Instrumentation: EPSRC has A number of these projects focus on and reliability, as well as real-time invested in a number of projects Additive Manufacturing: developing process control, is a particular focus to develop new manufacturing new design tools, challenging for this Centre. instrumentation; improve existing designer preconceptions and processes and develop new capabilities engaging the end-user in the in Additive Manufacturing. design process. Researchers at the University of Sheffield are creating a High Speed 29 Sintering machine capable of high The number of research part throughout and multi-materials £44m (see page 23), and a group at Keele organisations collaborating University are developing next- The amount invested generation 3D printers which can with EPSRC on Additive chemically pattern during production. by EPSRC in Additive Manufacturing-related If successful, this technology could Manufacturing-related have profound impact on medical research device and electronics manufacture. research

PIONEER 15 Summer 2015 27 Adding value From canine implants to DIY 3D printers, EPSRC-supported researchers are using Additive Manufacturing techniques to bring a host of diverse projects to fruition. They have also pioneered new AM technologies.

Metal masters The confidence and expertise the from the EPSRC Centre for Doctoral team developed when mastering this Training in Additive Manufacturing and Researchers at the University of Liverpool technology resulted in MTT Technologies 3D Printing who have worked on the have formed a company, Fusion Implants, commercialising the research and company’s projects. to manufacture high-performance designing, building and selling a machine. Dr Sutcliffe says: “Our lab at Liverpool is veterinary implants from titanium using The titanium components developed one of the largest in the UK, and we have Additive Manufacturing technology. included porous medical devices that plenty of experience and many firsts. are now used to make primary hip and The company’s patented technology “We built the first Additive Manufacturing knee joints by one of the largest implant builds on long-term research led by machine in the UK; helped develop companies in the world. “When we started Dr Chris Sutcliffe that allows the mass alongside Renishaw the first UK- to exploit our EPSRC-sponsored research manufacture of porous titanium material, manufactured metal 3D printer; and ours was one of 20 technologies from all enabling the animal’s bone to grow into invented and patented technology that has around the globe,” says Dr Sutcliffe. “Over the implant, forming a natural bond and led directly to the commercial implantation time we became the primary technology improving performance considerably. of thousands of series-produced advanced they invested in.” The company’s latest product, a 3D-printed implants.” MTT was acquired by Renishaw in 2011 surgical implant for use in canine knee and forms the backbone of its global reconstructions, is already being sold to AM business. Today, Chris Sutcliffe Concrete evidence veterinary practices. is Renishaw’s R&D director, a role he A team of EPSRC-sponsored engineers Dr Sutcliffe’s AM research dates from combines with academic research at the at Loughborough University, co-led by Dr the early 2000s, and through long-term University of Liverpool. Richard Buswell and Professor Simon collaboration with Renishaw, the UK’s Renishaw’s AM business is going Austin, developed an innovative 3D printing only manufacturer of metal Additive from strength to strength, and technique to create customised panels Manufacturing systems. the company recently expanded for large-scale buildings. The process One of the first EPSRC investments its Additive Manufacturing Centre was developed at the EPSRC Innovative was led by Professor Bill O’Neill at the into a new 90,000sq ft premises in Manufacturing and Construction Research University of Liverpool, to develop metallic Stone, Staffordshire. Centre at Loughborough. object construction using a specific Group Engineering Director Geoff The team have since developed 3D concrete Additive Manufacturing technique. McFarland says: “Working with EPSRC, printers fitted to a gantry and a robotic Further EPSRC-supported investments particularly through its Centres for arm. The printer can make things which followed, with Dr Sutcliffe driving new Innovative Manufacturing and Centres for cannot be manufactured by conventional research in areas such as selective laser Doctoral Training, allows us to take our processes such as complex structural melting (SLM) technology. pipedreams and talk to experts about how components, curved cladding panels and Sutcliffe used an EPSRC grant, part- they might be applicable to the real world. other architectural features. funded by medical devices company The hit rate is surprisingly high.” The team are collaborating with industry Stryker, to buy an advanced German The collaboration is two-way, with partners to commercialise the process, Additive Manufacturing machine to Renishaw staff often directly involved which could capture a significant share develop new, better SLM processes for in EPSRC projects. The company also of the US$450 billion global concrete and metals including titanium. has a track record of hiring graduates cement market.

PIONEER 0915 WinterSummer 2013 2015 28 RepRap revolution

In 2005, Dr Adrian Bowyer, an engineering researcher working with the University of Bath’s EPSRC-funded Innovative Design and Manufacturing Research Centre, was awarded a £20,000 EPSRC grant to build a 3D printer capable of replicating itself. The result was RepRap, a remarkable DIY 3D printer that, through the development of open source software, paved the way for a global community of people who could use RepRap machines to develop their own products. By 2007, Bowyer had established a global ‘virtual’ team of over 30 volunteer collaborators, from software developers to designers and mechanical engineers. In 2009, three RepRap volunteers from New York, Zach Smith, Bre Pettis and Adam Mayer, used the knowledge from the project to set up their own company, MakerBot – supported by a US$25,000 loan from Adrian Bowyer. Four years later, the company was bought by Stratasys, one of the world’s largest 3D printing companies, for US$403 million. The global DIY 3D printing market continues to grow exponentially, much of which can be attributed to one man’s vision and an EPSRC investment of £20,000.

Sole traders

Scientists at the University of Salford, working with East Lancashire Hospitals NHS Trust and Burnley company FDM Solutions, with support from EPSRC and Innovate UK, are developing made-to-measure insoles for the NHS using AM technologies. Hospitals will be able to scan a patient’s foot shape and e-mail it to the company, which will then 3D-print and deliver insoles to the exact specification within 48 hours. The process could revolutionise the way the NHS buys orthotics and other products. It could also improve quality and reduce consultants’ time, and transform supply chains in the NHS and other industries.

PIONEERPIONEER 0915 WinterSummer 2013 2015 29 The Centre uses eye-tracking technology during robot operation to monitor operator points of attention.

PIONEER 15 Summer 2015 30 i-Robot The EPSRC Centre for Innovative Manufacturing in Intelligent Automation is working at the cutting edge of the human/machine interface. Manufacturing will never be the same again – and the UK is in the front row.

BMW and Rolls-Royce are doing manufacturing processes previously there to expedite research so that it. Airbus has to do it. Germany is considered too difficult to automate. these companies can implement new spending vast amounts of money on Many of these technologies will practices quickly – making it one of it. And a growing number of smaller enhance and maximise the use of the the EPSRC Centres for Innovative manufacturing companies in Britain existing skill sets within the workforce Manufacturing with the biggest are now building a business case for rather than replace them. measurable impact on industry. automating manufacturing, using “We aim to robots and other system components radically improve to augment labour deployed on the effectiveness complex assembly tasks to improve of manufacturing productivity and competitiveness. operations in key Machines are more accurate and areas of UK industry, powerful than humans, they maintain working to meet quality control over time and they the needs both of do not get sick (or they need less large companies and ‘downtime’ than humans). manufacturing supply chains.” Automated Manufacturing is crucial to the future of a Factory automation is competitive manufacturing economy high on the agenda of in the UK, says Professor Mike global manufacturers Jackson, Director of the EPSRC such as Airbus, Rolls- Centre for Innovative Manufacturing Royce and Control in Intelligent Automation at and Data Services, Loughborough University. The Centre which are driven by was established in 2011 to investigate a definable business automation applications in industry need to speed up and to harness UK expertise in high value asset this field. manufacture without losing quality. It Partnered with Cranfield University, comes as no surprise the Manufacturing Technology Centre that these companies at Loughborough and also with are the Centre’s key industry, the Centre’s research aims industrial partners. to understand the level of human skill applied to difficult industrial Robots have manufacturing tasks and brings transformed together a unique blend of human productivity in the factors and mechatronics, which automotive sector, combines electronic and mechanical and their application Postural data capture allows detailed analysis and rerun of manual tasks. engineering. The Centre also studies in the UK is one of when automation is financially viable, the main for the relatively The Centre is also reaching out beyond a big issue for smaller firms. recent resurgent fortunes of Britain’s its existing network to the wider vehicle manufacturing industry – the manufacturing industry, especially Radical improvements UK is now a net exporter of cars. The smaller companies and SMEs. Professor Jackson says: “We are aircraft companies want to emulate working to develop automated parts of this; the EPSRC Centre is (Continued on next page)

PIONEER 15 Summer 2015 31 (Continued from previous page) manufacture, it comes into its own says: “Where people and robots mix Professor Jackson says: “Through our in the combination areas – where together you get the best of both EPSRC-funded outreach programme, humans interact with robots. worlds – the skill and adaptability SMEs are benefiting from access to “We look at the human skill in a of humans, and the brute force and the sort of research they wouldn’t manufacturing task, then we assess accuracy of industrial robots. normally get.” the degree of difficulty in automating “Naturally, when people work closely Musical instrument maker, Percussion that task,” says Professor Jackson. with automation, health and safety and Plus, is a case in point. The company’s “We then devise an intelligent solution regulatory compliance are priorities. Managing Director, Paul Cobbett, where there is likely to be a person “A key aspect of what we do is says: “Being involved with the robotics doing tasks that a human can perform investigate how humans work team at Loughborough and Cranfield better than a robot, and a robot doing with machines, and we look at the universities has been an enlightening tasks a human is not especially good consequences of these interactions experience, turning a seemingly at. Increasingly this involves a high on productivity, safety and impossible task, of winding our degree of machine . human welfare.” percussion beaters, into what would “For example, the robot can adapt by appear to be a practical possibility. The Centre is exploring what it calls measuring things in the environment, ubiquitous safety, where conventional “The team have been informative and with the appropriate computer guarding is removed and replaced by throughout the project; they are an code written by our system designers, sensory systems that continuously map amazing, eclectic group of people.” it can react, often in anticipation of the presence and location of operators. While the Centre’s research is expected changes.” The technology adjusts the degree of not relevant to fully automated Professor Phillip Webb, EPSRC Centre collaborative automation according to processes, such as high volume food Deputy Director at Cranfield University, the vicinity of the operators.

PIONEER 15 Summer 2015 32 Being able to work closely with automation systems that are inherently safe should improve the efficiency of the people operating the machinery and increase functionality/reduce the cost of automation. Challenges include the development of robust and effective monitoring systems and working through the processes for regulatory health and safety approval. The EPSRC Centre is driving this work forward, in the that this will be a cornerstone of future UK manufacturing automation. Catapult alignment Manufacturing, by definition, is all about the end product, and the Centre is an excellent example of how EPSRC-funded research dovetails with Innovate UK’s network of Catapults – technology and innovation centres where UK businesses, scientists and engineers work side by side on research and development, taking products to commercial viability. The Centre works closely with the Manufacturing Technology Centre (MTC), a Catapult Centre based at Ansty near Coventry, which helps companies develop prototypes at an advanced stage of technological readiness. In turn, the EPSRC Centre provides state-of-the-art facilities, cutting-edge research – and the talent to match. Professor Ken Young, the MTC’s Spot on: The Centre has conducted reviews of manual welding to inform the design of an intelligent automated welding system. Centre Director Professor Mike Jackson says: “We look at the human skill in a Technology Director, says: “The manufacturing task and then assess the degree of difficulty in automating that task.” EPSRC Centre creates a unique supply chain for talent in intelligent challenges to the EPSRC Centre innovations in production processes.” automation. These skills are not for the next generation of EPSRC- available to us from anywhere else Richard Mellor, Chief of Manufacturing supported research projects. This and will form a pivotal part of our Technology Operations, Controls and continuous bi-directional pipeline is future workforce.” Data Services, Rolls-Royce Group, central to our success and value, and Professor Jackson says: “We are part unique within the UK. says: “Working with the EPSRC of a unique pipeline from discovery Centre for Innovative Manufacturing in “By the end of 2016,15 projects we through to industrial deployment. Intelligent Automation has facilitated have initiated will be progressed Work initiated within an academic some very positive collaborations. to TRL 4+ (an advanced state environment can be developed through of technological readiness) and “The Centre has quickly built a an established innovation pathway, via supported for development by industry. knowledgeable team able to help with the Manufacturing Technology Centre and Cranfield partners, to reach major “Industrial partners in this research real challenges. Its strong alignment industrial companies with the funding have committed £1 million. They have with the Intelligent Automation theme and commitment to exploit the results. high confidence that funds invested at the Manufacturing Technology This pipeline is bi-directional to create through us will lead to a significant Centre provides a strong route feedback on advanced industrial positive financial return through new to exploitation.”

PIONEER 15 Summer 2015 33 PIONEER 15 Summer 2015 34 Hawking, drinking and bits of string

Theoretical physicist, Professor Jerome Gauntlett, from Imperial College London, who was the scientific consultant on the Oscar-winning Stephen Hawking film, The Theory of Everything, describes his days as a PhD student in Hawking’s Relativity Group, the power of string theory – and why he could have become a winemaker instead of one of Britain’s leading theoretical scientists.

I had a rather unusual education (DAMTP) at the University of There has been an extremely fruitful growing up in Australia, first attending Cambridge. From then on I have just interaction between theoretical a Montessori School for my primary followed my nose, taking postdoc physicists and pure mathematicians to education and then, for some of positions in Chicago and at CALTECH develop our current understanding of my secondary education, a small before returning to the UK. the subject. community school that my parents The biggest outstanding challenge It seems certain that there are deeper helped to set up. in fundamental is mathematical structures still waiting I had always liked maths and to find a consistent framework that to be discovered whose development astronomy but in a somewhat unifies Einstein’s theory of General will be essential in elucidating exactly haphazard way; it wasn’t until Relativity with the Standard Model what string theory is. I am currently I went to the University of Western of Particle Physics. Looking for such involved in an EPSRC Programme Grant pursuing this goal. Australia, where I did a joint maths/ a theory of has physics degree, that I realised that, challenged theoreticians for decades. I have also recently been pioneering in addition to playing football, my I have mostly worked on string theory, new techniques arising from passion was theoretical physics. or M-theory as it now also called, string theory, involving black holes, which remains a promising approach which may lead to new ways to I was awarded a Commonwealth for achieving this ambitious goal. think about real-world condensed Scholarship, which allowed me to do matter systems, such as high my postgraduate study in theoretical One of the most remarkable aspects of string theory is that it has produced temperature superconductors. physics at the Department of Applied It has been very stimulating enormously rich new mathematical Mathematics and Theoretical interacting and collaborating with ideas as well as deep insights into condensed matter physicists on this other aspects of theoretical physics interdisciplinary endeavour. such as black holes and quantum field theory. One aspect of theoretical physics that is not always emphasised is that it is a very social and collaborative effort. Over the course of my career I have been very fortunate to have worked with many talented and creative collaborators. (Continued on next page)

PIONEER 15 Summer 2015 35 disappointed that you can’t quite see the questions in the film, as the toughest was one which would be Hawking wheeled up to us very simple for a graduate student to answer today but very hard then! I also wrote up most of the equations on the and started typing valuable blackboards in various scenes and so they should be correct! lifelong advice: “Don’t ever I enjoyed meeting and talking with Eddie Redmayne, the actor who won get drunk on port” an Oscar for his role as Stephen in the film. He was keen to get a crash course in black hole physics and he was also very interested in discussing (Continued from previous page) some details about Stephen’s gestures I joined Stephen Hawking’s Relativity Stephen’s celebrity life start to take and movements. He did a phenomenal Group as a PhD student in 1987. off in earnest. I recall a particularly job capturing Stephen in the film. My supervisor was Professor Paul memorable Christmas party with There will always be very talented Townsend who is an inspirational Stephen, several members of the young scientists drawn to scientist and mentor. I worked on Relativity Group and Shirley MacLaine understanding the fundamental membranes and 11-dimensional trying to discuss “ energy”. of Nature but I think the career path supergravity, which at the time were I became involved in The Theory of is getting more difficult because of considered to be almost heretical Everything film when a colleague at the increasing pressure on securing topics. This all changed in the mid- Imperial, Professor Stephen Warren, funding for projects with short- 90s when these and other ideas were who knew someone working on term impact. appreciated to be key for developing a the film’s art production, made the The support I have received from deeper understanding of the structure connection that saw me being invited EPSRC, which includes both an of string theory. to work on the film as the ‘Theoretical Advanced and a Senior Fellowship, My first conversation with Stephen Physics Consultant’. There were has been very important in my career was when I was in the tea room several aspects of my involvement, and I am very grateful. Government commiserating with another student including providing various input about investment in research in blue-skies over our hangovers. Stephen wheeled the scientific content of the script. fundamental sciences is critically up to us and started typing while we There are many different kinds of films important. I am concerned that the went deathly silent. He then gave me a that you can make about Stephen and ‘Impact agenda’ puts such support lifelong valuable piece of advice: “Don’t this is just one of them; while I think it under threat. History has repeatedly ever get drunk on port”. My now wife, is a very good film, it is certainly not a demonstrated that progress in Professor Fay Dowker, was Stephen’s scientific documentary. That being said science, and also in technology, is PhD student at the time and this it does touch on many of Stephen’s very hard to predict. The biggest provided another contact with Stephen. major achievements. developments often come from The scientific atmosphere was There is a scene in the film when completely unexpected areas. If 19th incredibly stimulating. Important Stephen is given 10 hard questions century funding bodies were seeking progress was happening in several to answer. To demonstrate (in a very to improve communications, they different directions led by Stephen, stylised way) how clever Stephen might have entertained the idea of other scientists at DAMTP, as well is, he starts working on them a investing in breeding programmes as the vast retinue of eminent couple of hours before the deadline to make pigeons fly faster and to international visitors. The impact and then ends up answering nine have increased endurance, rather of Stephen’s best-selling book, of the questions. I had to write up than support James Clerk Maxwell’s A Brief History of Time, was just 10 reasonable questions and model esoteric ideas on electricity beginning and it was fascinating to see answers for this scene. I was slightly and magnetism!

PIONEER 15 Summer 2015 36 Understanding the fundamental laws see how much enthusiasm there is for moment is theoretical consistency of Nature is one of humanity’s greatest science among young adults. but one can hope that there will also cultural achievements, and I believe I think one day there will be a Theory be significant experimental input in that everyone should have access to of Everything in the sense of a the future. It is less clear, though, this knowledge. Outreach events are whether such a unification would be one way to achieve this, the final word concerning the and I regularly give fundamental laws of Nature. public talks and also talks at schools, both I wrote up most of the If I hadn’t become an secondary and primary. academic I might now be Around the time The a winemaker. I did not get Theory of Everything equations a postdoc position the first was released I gave time I applied – perhaps due several science talks on the blackboards in the to the fact that my PhD was titled A Brief History focused on topics which were of the Science of unfashionable at the time. If Stephen Hawking. film’s various scenes I had also been unsuccessful This provided a nice the second time around complement to the film, I would have gone back which concentrates to Australia and, at least on Stephen’s personal story. One of consistent unification of the Standard to begin with, would have these was an ‘adults only’ event at the Model and General Relativity. The main helped my parents make wine on Science Museum; it was wonderful to guiding at our disposal at the their vineyard.

(Almost) The Theory of Everything in 450 words

The two cornerstones of theoretical physics are forget about it. Similarly, General Relativity is applicable Quantum Theory and Einstein’s Theory of General on very large scales when all other particle forces are Relativity (our theory of gravity). negligible. This is why we can have the two incompatible Quantum mechanics describes the physics of the really theories happily co-existing. small: atoms, electrons, protons and all of the particles However, we know that there are some situations where observed when these particles are smashed into each we need both theories: for example inside black holes and other at very high energies in particle accelerators. It is at the Big Bang, billions of years ago. A theory that unifies a very weird world, in which particles sometimes behave the two is called a theory of quantum gravity and would like waves and waves sometimes behave like particles. unify the fundamental laws of Nature. My work focuses But the weirdness is really there, and has been tested to on a particular approach to quantum gravity called string incredible precision. theory. Originally the key idea of string theory was that the Three of the four known forces in the universe are most fundamental constituents of matter are extremely quantum mechanical in nature: electromagnetic, weak small one-dimensional objects, called strings, which nuclear and strong nuclear. These forces are described would have no further sub-structure. The idea is that by the Standard Model of particle physics. The fourth different vibrations of the string would give rise to all of force, the phenomenon we know as gravity, on the other the observed elementary particles as well as new ones to hand, is quite different. be discovered. Einstein’s Theory of General Relativity explains how the A remarkable aspect of string theory is that it is defined curvature of spacetime is responsible for gravity, and in 10 spacetime dimensions. We now know that there accurately predicts the of black holes, whose is a deeper structure, called M-theory, which includes curvature is so extreme that not even light can escape. membranes and other extended objects and the theory General Relativity is also the basis for our theory of the also exists in 11 spacetime dimensions. origin of the universe – the Big Bang. The study of string theory has produced enormously So, two beautiful theories, the Standard Model and rich new mathematical ideas, as well as deep insights General Relativity, and both very accurate. But... they are into other aspects of theoretical physics such as black mathematically incompatible. holes and quantum field theory, which are likely to be important in future developments irrespective of whether How can this possibly be? The resolution is that the two or not string/M-theory turns out to be the theory of theories are associated with very different scales. On quantum gravity. small scales – that of atoms and electrons in current particle physics – gravity is so weak that we can just Jerome Gauntlett

PIONEER 15 Summer 2015 37 RESEARCH IN THE WORLD

Earthquake damage in Kathmandu. Joshua and the SARAID team were among the first international rescue teams to arrive. International rescue Doctoral student Joshua Macabuag (pictured below) put down his research into tsunami effects at the EPSRC-sponsored EPICentre at UCL (University College London) to help rescue victims of the Nepal earthquake this April. He tells Pioneer about his work with the charity SARAID (Search and Rescue in Disasters).

I was on a training We were one of the first teams to been sensationalist, concentrating on exercise with three arrive in Kathmandu, despite hold ups areas with serious damage. The chaos other SARAID in New Delhi spent finding an onward getting there had also built up the volunteers when flight that could take us and our two tension. From the air, flying in at night, news of the Nepal tonnes of kit. we could see fires where Nepalis were earthquake came cremating their loved ones. But it was through. Down in Cornwall, and It was frustrating, waiting in the transit unexpectedly quiet when we arrived in out of mobile contact, we didn’t get lounge knowing there would be people Kathmandu. The city was functioning. the ops director’s message until dying in the rubble. Larger teams took The destruction was restricted to around midday. even longer to arrive. small pockets. We headed straight back to London It was my first deployment with My role on the team is as an engineer. to be ready to fly to Nepal at a SARAID, and I was surprised by the Like the technicians, I do the heavy moment’s notice. eerie calm. The news broadcasts had work with drills and other kit to get

PIONEER 15 Summer 2015 38 into damaged buildings and find make the local mud-walled homes the inspirational leader of UCL’s survivors, but engineers have the more resilient to earthquakes. I led on EPICentre, an EPSRC-funded hub additional responsibility of assessing the design of a low-cost wall-cladding of multidisciplinary expertise on whether it is safe to go in, what way system using the kind of polypropylene disaster prevention. to go, and whether the structure mesh you find in flatpacks. The I had always intended to return needs stabilising. buildings’ retrofitting is very simple – to academia after a stint in the On our first day in Kathmandu, we so as to be as affordable as possible, commercial world. Looking for were directed to some hotels and yet be robust enough to withstand places to study for my PhD, I saw other residences that had collapsed; earthquake. lots of options, but very few choices; these were better tackled with hands When this year’s international search- EPICentre was number one. My and spades rather than our specialist and-rescue missions had ended, research there, studying for an kit. They were relatively small and the Nepalese government asked for EPSRC-sponsored Engineering built with light materials that were engineers to stay on to assess the Doctorate, is closely related to not difficult to move. Also, victims safety of key buildings, like schools what I saw in Japan – studying the inside would either already have been and hospitals. I quickly volunteered. resilience of buildings against the rescued or would have perished, as This also gave me the chance to return forces of tsunamis. the mounds of debris would have to the historic town of Bhaktapur. Academia gives me the stability I need left them no voids to survive in. The The mud render of our two-storey to commit to SARAID. The training is following day, with more teams arriving demonstration house was cracked, very intensive – a full weekend every from around the world, we divided the but the walls had survived, and the month. When consulting, I might be city up into radial sectors, and began a building stood. sent on an assignment abroad for more systematic search. The 2008 project, at the start of my weeks on end, which could not be In the end, around 2,000 international engineering career, saw me later matched with that commitment. volunteers came to Nepal’s assistance; joining the charity Engineers without If anything, international aid will need but found only five survivors alive, Borders, through which I learned to move faster next time there’s a because it was so hard to get there about SARAID. I also joined an EEFIT disaster like this earthquake, which in time. Nevertheless the people of [Earthquake Engineering Field will mean better organisation, and Kathmandu were really appreciative Investigation Team] reconnaissance better intelligence ahead of time. But – our efforts showed the world was mission to Japan to study the tsunami it’s hard to know how that can be done focused on their plight. damage in 2011. when there’s a whole world to watch. I first visited Nepal in 2008. I’d gone to It was through EEFIT that I met a rural area just outside Kathmandu Professor Tiziana Rossetto, on an engineering education programme to test ideas I’d developed as a student at Oxford to

PIONEER 15 Summer 2015 39 RESEARCH IN THE WORLD Wee will rock you Step aside Kanye, a urinal that generates its own electricity was one of the biggest crowd pleasers at Glastonbury 2015.

The annual wonder-gig that is and dangerous places, particularly of the Bristol BioEnergy Centre located Glastonbury Festival is guaranteed to for women. in the Bristol Robotics Laboratory (BRL) make the headlines. If the performers at the University of the West of England The power comes from microbial fuel don’t make it to the front pages, the (UWE). The technology builds on weather often takes centre stage. cell (MFC) stacks inside the toilet EPSRC-supported research. Or the toilets. Sometimes both. In 2010, EPSRC awarded a In addition to first-time four-year Career Acceleration Glastonbury performances by This technology is about Fellowship to Professor Ieropoulos the likes of Lionel Richie and to develop his research into MFCs. Kanye West, the 2015 festival In the same year, the BRL team saw the debut of a remarkable as green as it gets launched the third generation of new sanitation facility – a toilet EcoBot, a robot which can power block that needs no external itself by digesting waste. They later power source to light its cubicles, block. Live micro-organisms inside proved that MFCs could also power instead relying on pee power to mobile phones. the fuel cells process the waste to generate electricity. produce electricity. Professor Ieropoulos says: “The Among its potential uses, it is hoped microbial fuel cells work by employing the technology will light cubicles in The invention is the brainchild of live microbes which feed on urine (fuel) refugee camps, which are often dark Professor Ioannis Ieropoulos, Director for their own growth and maintenance.

PIONEER 15 Summer 2015 40 “The MFC is in effect a system which a buzz. Toilets are always a talking make the trial as realistic as possible taps a portion of that biochemical point at this festival, but I think this one the urinal resembles toilets used in energy used for microbial growth and tops the lot.” refugee camps by Oxfam. converts that directly into electricity. It University student, Eleanor Kirwan, who Andy Bastable, Head of Water and can utilise any form of organic waste spent four days camping at this year’s Sanitation at Oxfam, says: “Oxfam and turn it into useful energy. What’s festival, says: “I think this technology is an expert at providing sanitation more, MFCs are like batteries that do is brilliant. I am a big fan of festivals in disaster zones, and it is always not run out. such as Glastonbury but I’m more than a challenge to light inaccessible “This technology is about as green as aware of the sometimes detrimental areas far from a power supply. This it gets, as we do not need to utilise effects that they can have on the technology is a huge step forward. fossil fuels and we are effectively using environment. It’s great that technology Living in a refugee camp is hard a waste product that will be in enough without the added threat of plentiful supply. being assaulted in dark places at night. The potential of this “Not only is the technology a invention is huge.” means of electricity generation, it The potential of this can also improve sanitation. The Professor Ieropoulos says: “One microbial fuel cell costs work carried out under the EPSRC invention is huge about £1 to make, and a small grant is primarily focused at unit like the UWE facility could developing this technology for the cost as little as £600 to set up, developed world.” Andy Bastable, Head of Water and Sanitation, Oxfam which is a significant bonus This is no small beer, and not as this technology is in theory just for festival-goers. Every everlasting.” day, around 38 billion litres of urine being trialled at the festival could have The Bill & Melinda Gates Foundation such large-scale impact in the future.” are produced by humans and farm also supports the project, and has animals worldwide. The bespoke toilet block, donated by awarded BRL two grants totalling Interviewed on Day One of Glastonbury timber construction experts, Dunster US$1.1 million under the Grand 2015, Jane Healy, the festival’s House, builds on an earlier project, also Challenges Explorations Scheme to sanitation manager, said: “For me, pee in partnership with Oxfam, centered help the team investigate generating power is the future. Everyone at the around a urinal strategically situated electricity from urine and wastewater festival is talking about it. It has created near the student union bar at UWE. To for countries of the developing world.

PIONEER 15 Summer 2015 41 In profile Professor Karen Holford Pro -Chancellor Physical Sciences and Engineering, Cardiff University. A member of EPSRC ‘s Strategic Advisory Network, Karen chairs EPSRC’s Engineering Strategic Advisory Team.

What is the most fascinating aspect of How close are we to seeing gender got it right. Fortunately I have a hugely your research? equality in the lab? supportive and very good friends; Discovery is what drives me. My research Recent high profile events have highlighted they know when to tell me that I am aims to improve techniques for damage the subtle, and not so subtle, inequalities getting it wrong. I find the best way to get detection in structures – these can that still exist. On the face of it, we have a balance is to try to prioritise what is include bridges, wind turbines and aircraft processes in place that help to ensure that important at any time and to constantly components such as landing gear. I find all people are treated equally in terms reassess the priorities. it fascinating to work with brilliant people of recruitment and employment. But If you were sent to a desert island, what who are full of ideas; the process of unconscious and in particular sexist three things would you take with you? attitudes and comments are still holding us working in a team to solve a problem and A toolbox so I can have shelter, food and back and putting women off from choosing the sense of achievement when you find water. Then I’d need so I’d to enter or remain in careers in science, something new that no one has discovered like a solar-powered radio with winder and technology and mathematics. before are both important to me. a football. It is vital to promote equality by modelling What is the most important topic in What advances in science and technology good behaviour; influential intellectuals your field? would you like to see? should be very sensitive when speaking In engineering there are a multitude of As a sci-fi fan it has to be the teleportation about gender issues in public. really important challenges of profound machine (transporter). There are many importance to society. When EPSRC Workplace banter is changing; influential situations where it would be incredibly recently ran workshops to consult people have challenged racism and convenient to say: “Beam me up, Scotty”. homophobia to the point where it is the academic community on the most What single item can’t you do without? important challenges, it was interesting no longer socially acceptable and I am For most people it’s the iPhone; I am to see the big issues that always came optimistic that by challenging sexism it too no exception – both personally and up; energy, food, water, security, health can be made socially unacceptable. professionally. It’s a great example of the and global warming. The consequences What drew you to pursue a career in technological advances scientists and to society of not supporting engineers and mechanical engineering? engineers have made over the last 20 years. scientists to makes discoveries to solve I have always been fascinated by Liverpool season ticket or access all these problems are profound. technology. I was an extremely curious areas pass to the British F1 Grand Prix. You chair EPSRC’s Engineering Strategic child and I was often asking questions Choose one. Advisory Team (SAT). What does this role that people couldn’t answer, so I looked mean to you? for the answers myself. This set me That is the most difficult question in this entire interview! OK, this season I’ll have The SAT comprises academics, industry up for a career searching for answers. the GP pass and next season I’ll watch and other experts in engineering, and My dad had a garage so I was also very every Liverpool home game, please. advises on EPSRC’s research and training practical and used to help him out strategy. EPSRC needs these advisers. regularly. His influence, combined with They act with integrity to ensure that my natural curiosity, kept me engaged EPSRC gets appropriate advice to assist it right throughout secondary school, and In short in the development of its plans for research I became the first person in my family to go to university. Professor Holford is a Chartered and training, to make it aware of new Engineer; a Chartered Physicist; opportunities and to help to communicate If you hadn’t become an academic, what Fellow of the Learned Society of key messages. We also provide a good would you be doing now? Wales and Fellow of the Women’s sounding board for new ideas. My role is I’d like to think I would be manager of a Engineering Society. important to me because of the significant Premier League football club. Or I’d be Among her achievements, she role that EPSRC plays in shaping and a retired Formula 1 driver. My interest in pioneered new acoustic emission supporting the UK as a world-leading Formula 1 comes from my parents – they structural monitoring technology in research nation. both loved motorsport and used to take us conjunction with MISTRAS, providing Does EPSRC listen to the SAT’s advice? all (four daughters!) to the British Grand solutions for bridge inspection without Prix. Motor sport is exciting but what Always! I should point out that the role of the the need for costly shutdowns. I really like is that it pushes engineers to SAT is to advise, not to make decisions. The be innovative and creative. The engineering She is passionate about encouraging important thing here is that EPSRC always in F1 cars is truly breathtaking. young people to study engineering and strives to obtain a range of perspectives science, especially girls, and works from as many people as possible, balanced How do you balance your work and closely with the Women’s Engineering against the time taken to do so. The SAT ? Society and Women in Science and provides one input and I think it is an This is the most difficult and delicate Engineering to help achieve this. efficient means of obtaining timely advice. balance to achieve, and I haven’t always

PIONEER 15 Summer 2015 42

Total value of EPSRC’s research and training portfolio: £4.6 billion

Total invested by business and other partners: £1.74 billion

Total invested in research and training annually: £800 million

Organisations involved in collaborative EPSRC grants: Over 3,150

Percentage of research portfolio that is collaborative: 53% About EPSRC

About the Engineering and Physical Sciences Research Council (EPSRC) As the main funding agency for engineering and physical sciences research, our vision is for the UK to be the best place in the world to research, discover and innovate. By investing £800 million a year in research and postgraduate training, we are building the knowledge and skills base needed to address the scientific and technological challenges facing the nation. Our portfolio covers a vast range of fields from healthcare technologies to structural engineering, manufacturing to mathematics, advanced materials to chemistry. The research we fund has impact across all sectors; it provides a platform for future economic development in the UK and for improvements for everyone’s health, lifestyle and . We work collectively with our partners and other Research Councils on issues of common concern via Research Councils UK. www.epsrc.ac.uk Follow us on: www.twitter.co.uk/EPSRC

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