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The Current Landscape for Additive Manufacturing Research

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The Current Landscape for Additive Manufacturing Research THE CURRENT LANDSCAPE FOR ADDITIVE MANUFACTURING RESEARCH A review to map the UK’s research activities in AM internationally and nationally 2016 ICL AMN report Dr. Jing Li Dr. Connor Myant Dr. Billy Wu Imperial College Additive Manufacturing Network Contents Executive Summary .............................................................................................................. 1 1. Introduction .................................................................................................................... 4 2. What is additive manufacturing? .................................................................................... 5 2.1. Advantages of additive manufacturing ......................................................................... 5 2.2. Types of additive manufacturing technology and challenges ........................................ 6 2.3. The manufacturing production chain and challenges ................................................... 9 2.4. Conclusions ................................................................................................................12 3. Mapping the international additive manufacturing research landscape ......................... 13 3.1. Global market trend ....................................................................................................13 3.1.1. Growth in market value ........................................................................................13 3.1.2 Additive manufacturing growth in industrial markets.............................................14 3.1.3 Geographic trends ...............................................................................................15 3.2 Global research trend .................................................................................................15 3.2.1 What is the overall trend throughout years? .........................................................15 3.2.2. What are the top countries that works on additive manufacturing? .......................16 3.2.3. Who are the top organisations worldwide that work on additive manufacturing? ..18 3.3 Conclusions ................................................................................................................21 4. Mapping additive manufacturing research activities nationally in UK ............................ 23 4.1. What is the overall additive manufacturing research trend nationally? ........................23 4.2. How much total funding is allocated for additive manufacturing research in the UK? ..23 4.3. Who are the leading organisations that work on additive manufacturing in the UK? ....26 4.4. What is the geographic distribution of academic research? .........................................29 4.5. What is the technology focus within research in UK universities by funding? ..............32 4.6. Conclusions ................................................................................................................34 5. Detailed analysis on selected UK Universities for additive manufacturing .................... 37 5.1. Available additive manufacturing equipment in the selected UK universities? .............37 5.2. How much funding is received by selected university? ................................................39 5.3. What is the research focus? ........................................................................................40 5.4. Overview .....................................................................................................................43 5.6 Conclusions ................................................................................................................44 6. Conclusions ................................................................................................................. 46 7. Acknowledgements ...................................................................................................... 48 i 8. References .................................................................................................................. 49 9. Appendix ...................................................................................................................... 54 9.1. Methodology and data for Chapter 3 ...............................................................................54 9.2. Methodology and data for Chapter 4 ...............................................................................54 9.3. Methodology for Chapter 5 .............................................................................................71 ii List of Definitions/ Nomenclature 2PL Two Photon Lithography MMJ Multi Material Jetting ABS Acrylonitile butadiene styrene MTC Manufacturing Technology Centre AM Additive manufacturing MWF Metal Wire Feed BAAM Big area additive manufacturing OEM Original equipment manufacturer BJ Binder jetting OIJ Organic Ink Jetting CAD Computer aided design PBF Powder bed fusion CAGR Compound average growth rate PIJ Polymer Ink Jetting CBJ Ceramic Binder Jetting PJ Polymer Jetting CLIP Continuous light interface production PLA Polylatic acid CNC Computer numerically controlled PWC PricewaterhouseCoopers DED Direct Energy Deposition RCUK Research Council UK DIY Do it yourself RDM Redistributed manufacturing DMLS Direct metal laser sintering ROW Rest of the world DSTL Acrobat Distiller RP Rapid prototyping EBAM Electron beam additive SIG Special Interest Group manufacturing SLA Sterolithography EBM Electron Beam Melting SLM Selective laser melting EPSRC Engineering and Physical SLS Selective laser sintering Sciences Research Council SMD Shaped Metal Deposition EU European Union STL Stereolithography File Format FDM Fused deposition modelling TRL Technology Readiness Level HSS High Speed Sintering TWI The Welding Industry HVM High Value Manufacturing UAM Ultrasonic Consolidation ICL Imperial College London UK United Kingdom IP Intellectual property UOC University of Cambridge IS Infrared sintering UON University of Nottingham LMD Laser Metal Deposition UCL University College London LMJ Liquid Metal Jetting UOS University of Sheffield LU Loughborough University US United States MBJ Material Binder Jetting Vat-P Vat-photo Polymerisation ME Material Extrusion WAAM Wire and arc additive manufacturing MJ Material Jetting WIJ Wax Ink jetting Version 1.0 iii Executive Summary This report outlines the current status of additive manufacturing (AM) research internationally and nationally, with a focus on the strengths, weaknesses, opportunities and threats posing UK AM research. AM is a technique which enables the creation of complex 3D objects, previously not possible with traditional subtractive manufacturing. It has been identified by the government as one of the key technologies required to enable high value manufacturing in the UK. The technology has in recent years entered into applications such as medical, aerospace and automotive due to innovations in materials and processing technologies, yet there are still many technical challenges that must be overcome in order to achieve a higher market penetration. With regards to materials processing and printing technologies, these have been identified as: The need to increase dimensional accuracy and repeatability of parts potentially through in-situ metrology and combined model based approaches. Limited material options necessitating the need for new materials. Methods which enable cost reductions and increase build speed, and size, of parts. However, beyond the machines, there are also many research challenges that need to be addressed across the production chain that are often overlooked, including: Improved software tools which are capable of handling the geometric complexities of designed components. Supporting design tools and methodologies which aid with the design for AM process to unlock the true potential of the technology. The need for improvements in the pre- and post-processing technologies and approaches. Limited work relating to digital ownership and standardisation. Globally, the UK is within the top 4 countries working on additive manufacturing; accompanied by the US, China and Germany. Within the EU, AM is clearly a priority area with €160 million worth of research funding invested, much of which the UK is involved with [1]. In the UK, the current EU funding in AM currently represents 18% of available funds and with the UK’s decision to leave the EU, it is important to ensure that future research funds are secured to ensure the health of this research area. In the UK, there are research activities across the various additive technologies, with more of a focus on low-mid technology readiness level (TRL) works. However, whilst there is this focus on novel technologies the translation of this research into commercial impact has, thus far, been limited and there is a need to bring together the excellent fundamental science base in the UK with the industrial applications in AM. Funding within the UK has been shown to exhibit a long tail effect, with a small number of institutions, mainly in the Midlands, receiving the majority of the research funding, though there are signs that this is shifting. Whilst, there is a healthy amount of industrial engagement, there is also evidence that there is limited cross-pollination of research activities. Thus, the UK has been shown to have significant capabilities in additive manufacturing, however the need for improved collaboration has been identified on top of the research challenges. 1 2 3 1. Introduction AM has been identified as being one of the key enabling
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