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Engineering an Assault on the World's Oldest Trophy 160 years of innovation theengineer.co.uk September 2016 FIRST FOR TECHNOLOGY & INNOVATION Plane sailing Engineering an assault on the world’s oldest trophy N • 1 O 6 I 0 T Y A E V A O R N S N I O F & E G N N G I I R N E E Can you dig it? Manufacturing talk Green sky JCB’s chief innovation Lord Bhattacharyya The technologies offi cer discusses on Brexit, steel and that are set to the company’s future opportunities make civil aviation brand-new machine »28 for the UK »32 more effi cient »55 66 »Careers feature A demand for technical skills means opportunities are opening up in the renewables sector TE_010916 1 08/09/2016 10:27 Shorten your development time with speed and accuracy. 3D CAD online ordering can mean same-day manufacturing! Our CNC turning and milling use a range of engineering-grade plastics and metals, including so metals and steel. Our quick turnaround times mean that you won’t lose valuable development time. Get 1 to 200+ parts in 3 days or less. 3D PRINTING | CNC MACHINING | INJECTION MOULDING Rhys Wilkinson Account Manager protolabs.co.uk +44 (0) 1952 683047 Order online anytime | Free design analysis [email protected] Protolabs_FP_TE_010916.ps 1 02/09/2016 14:38 editor comment thisissue ouropinion Volume 297 Issue No.7879 Established 1856 Going with the flow news 05 Manufacturing Demonstration of additive ambition 06 Aerospace UAV carries thermal camera that can locate people n recent years, many have claimed that the once-famed flow of technology from top-flight motorsport to the wider automotive world – the so-called 08 Transport Inexpensive sensors ‘race-to-road’ phenomenon – has slowed to a trickle. for safety at level crossings But while it’s possibly true that there are fewer direct technology spin-offs today from competitions such as Formula One, the substantial 10 Electronics Modified bacteria flow of skills and expertise from the sector is often overlooked. produces smallest-ever nanowires We saw a particularly high-profile example of this earlier in the summer, 12 Electronics Wrinkled graphene where the astonishing Olympic medal success of team GB’s track cyclists arguably owed as much to the exacting technical focus of a team led by sheets could conduct electricity former Jaguar and Red Bull Formula One principal Tony Purnell as it did 14 Aerospace Project could help to to the cyclists themselves. In this issue we take a look at another sport benefiting from the refined focus revolutionise aircraft maintenance of Formula One engineering: sailing’s America’s Cup – the world’s oldest sporting trophy and an event that, in recent years, has evolved into something of a showcase opinion for cutting-edge technology. Bristling with sensors, flying above the waves on advanced hydrofoils and propelled 16 Viewpoint Gregg Butler by giant ‘wings’, today’s America’s Cup yachts have more in common with fighter 18 Mailbox Your letters to the editor jets than with the lumbering mono-hull vessels that have dominated much of the 20 Paul Jackson Behind the scenes sport’s history. And in this issue’s cover story (p22) we take a look at the role that engineers are 32 Interview Lord Kumar Bhattacharyya playing in Land Rover BAR’s bold effort to wrestle the trophy from its current holders 34 Scifi eye Driverless cars and bring it back to Britain. features “ While there are now fewer direct 22 Cover story Mounting a challenge spin-offs, the flow of expertise on the world’s oldest sailing trophy 28 Feature Reshaping the future of from Formula One is overlooked” urban construction As team CEO and former McLaren racing boss Martin Whitmarsh explains, it’s 36 Measurement a highly collaborative effort bringing together a multitude of industrial partners and 42 Fastening and joining underpinned by a fascinating relationship between Whitmarsh and the team’s leader, sailing legend Ben Ainslie. 55 Aerospace Staying on the subject of collaboration, we’re delighted to announce the winners 66 Careers Renewables of The Engineer’s inaugural Collaborate To Innovate awards. You can see the full list 76 Archive of winners in this issue (p79) and find out much more about their projects at our special Collaborate to Innovate conference on 17 November at Coventry’s 78 Digest Manufacturing Technology Centre. Visit conferences.theengineer.co.uk to find out more. Your number-one website for engineering news,views, jobs and products theengineer.co.uk Jon Excell Editor [email protected] UK subscriptions £75 pa UK/£117 pa overseas. Order online at www.theengineer.co.uk/subscribe or by telephone Centaur Media Plc, 79 Wells Street, London, W1T 3QN on +44 (0207) 292 3705. All rights reserved. No part of this publication may be reproduced in any form without prior permission from the publisher. Direct dial 020 7970 followed by extension listed Advertising fax 020 7970 4190 Editor Jon Excell (4437) [email protected] Features editor Stuart Nathan (4125) [email protected] Senior reporter Andrew Wade (4893) [email protected] News editor Jason Ford (4442) jason.ford@ ISSN 0013-7758. Printed by Headley Brothers Ltd, centaurmedia.com Senior art editor Phil Gibson (4135) [email protected] Recruitment advertisement manager Ben Cogger (4187) ben.cogger@ Ashford TN24 8HH Visit www.theengineer.co.uk for centaurmedia.com Account manager Sarah O’Shea (4160) [email protected] Senior sales executive Jason Padam (4677) Sales executive Kennedy constantly updated news, products and jobs and to Ogbanufe (4811) Commercial director Sonal Dalgliesh (4487) [email protected] Commercial manager Peter York (4942) Business development sign up for our FREE weekly email newsletter and manager James Rushford (4487) Production Lyndon White, Wendy Goodbun (4807) [email protected] Publisher Simon Lodge (4849) tailored job alerts [email protected] Subscriptions & Customer Services [email protected] The Engineer is available for International licensing and syndication. For more information please email [email protected] NEWS 020 7970 4442 DISPLAY 020 7970 4487 RECRUITMENT 020 7970 4110 SUBSCRIPTIONS/CUSTOMER SERVICES HOTLINE 020 7292 3705 SEPTEMBER 2016 | THE ENGINEER 3 TE_010916 3 08/09/2016 11:19 Your One-Stop Shop for Process Measurement and Control Products • 100,000 products online • Easy online ordering • Same day shipping oonn iinstocknstock iitemstems • FullFull technicaltechnical supportsupport 6 Channel Data Logger RDXL6SD handheld temperature data logger with 4 type J, K, T, E, R, S or N thermocouple inputs and 2 3-wire Pt100 RTD inputs Thermo-Hygrometer RH700 measures humidity, moisture, temperature and pressure values Pressure Products Includes switches, load cells, strain gauges, controllers, recorders, dataloggers, transducers, and much more Temperature Probes and Assemblies For all environments and applications omega.co.uk 0800 488 488 [email protected] Temperature Pressure Automation Flow DAS pH Heaters © COPYRIGHT 2016 OMEGA ENGINEERING,LTD. ALL RIGHTS RESERVED Omega_FP_TE_010716.ps 1 19/05/2016 17:46 news technology Readmoreonline MANUFACTURING [further] reduce our cycle times. “Some tools can take months to Automotive Demonstration of make. Now, if we can reduce that to Volvo and Uber join forces days for a printed tool, we can start on driverless taxi plan to look at reducing or eliminating the time associated with making additive ambition prototype tooling and eventually Civil & structural production tooling.” Metamaterials could Technology demonstrators interest aerospace Stratasys’ Robotic Composite 3D Demonstrator, developed in lessen earthquake effects JASON FORD REPORTS and automotive companies conjunction with Siemens, removes steps such as manual lay-up and Defence & security curing in an autoclave to produce How the sector helped tratasys has broken low-volume, lightweight parts. composite parts in 3D. Team GB cyclists to cover on technology Ford Motor Company is also Garrity added that the traditional pedal to success demonstrators investigating automotive manufacturing composite process could be difficult designed to realise applications for this demonstrator and in terms of scaling, and rendering large, additively will evaluate the new technology. the types of detail that were often Electronics & manufactured (AM) Furthermore, Ford and Stratasys required in parts. communications parts and facilitate will work together to test and develop By comparison, the Robotic Princeton develops Scomposite components without new applications for automotive-grade Composite 3D Demonstrator delivers 25-core chip for servers incurring the penalties associated 3D-printed materials that were not 3D printing by using an eight-axis with producing such components. previously possible due to limited size. motion system (a six-axis robot with a According to the company, the Dr Ellen Lee, technical leader, two-axis rotary positioner) that enables Energy & environment Infinite-Build 3D Demonstrator and additive manufacturing research at precise, directional material placement Low-cost battery has Robotic Composite 3D Demonstrator Ford Motor Company, said: “What for strength, while also reducing the potential for grid storage build on Stratasys’ expertise we’ve been doing in the past – need for support structures and in industrial fused deposition prototyping, design verification and eradicating layer transitions. modelling (FDM) 3D printing to help looking at quick iterations for designs “We’re not in the business of Manufacturing manufacturers design and build parts – has helped us to be more efficient inventing a specific output,” said Security must be top of with credible structural integrity but at and reduce our cycle times. Ilan Levin, Stratasys CEO. manufacturing agenda a fraction of the time and cost. “Now, we’re looking at more “What we are trying to do is identify Common to both demonstrators is functional applications. This is because applications and deliver upon those an approach to FDM extrusion that additive manufacturing gives us… applications as best we can, and Medical & healthcare increases throughput and repeatability.
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