This project will investigate and develop novel and interlinked measurement-enabled technologies for realising the next generation of factories for the "Assembly, Integration and Test" (AIT) of high value products. The vision is for the widespread adoption and interlinked deployment of novel, measurement-based techniques in factories, to provide machines and parts with aspects of temporal, spatial and dimensional self-awareness, enabling superior machine control and parts verification. The title "Light Controlled Factory" reflects the enabling role of optical metrology in future factories. The scientific and technological challenges that would need to be addressed via this research to realise this vision include: (a) Future AIT factories require product specific customisation of assembly, ultimately adapting the condition of assembly for each part, whilst ensuring assembly integrity and high process yield. The research challenges are; (i) to develop methods using accurate high frequency measurement data to control the position and orientation of parts in real-time, and (ii) to integrate semi-finishing processes with assembly, such as machining, without adversely impacting the spatial fidelity of parts and machines. (b) Within AIT factories, the effect of gravitational deflection and the impact of the environmental thermal gradient on large components and tooling structures can be significant and larger than the assembly tolerances. In such cases the dominant dimensional uncertainty source is often the effect of the environment on the parts and the structure of assembly equipment. Currently, industry has no robust mechanisms for identifying the impact of environmental uncertainty sources when seeking to demonstrate assembly conformance to design, with major consequences in terms of product verification. (c) In order to integrate, control in real time and verify heterogeneous processes within an AIT factory it is essential to develop novel metrology networks that are scalable, affordable and can be used to create measurement-enabled production processes of superior process capability, and also to verify parts. The research challenges include; the real time fusion of measurement and uncertainty data from multiple systems, the mitigation of environmental effects through local and large volume measurement, and the definition of generic network design principles underpinned by algorithms for measurement uncertainty. The project is important to the UK as the technologies deployed relate to the "systems modelling and integrated design/simulation" national competency and address the "flexible and responsive manufacturing" strategic theme according to TSB's document entitled 'A Landscape for the Future of High Value Manufacturing in the UK'. Strategically this proposal fits into the Manufacturing the Future theme of EPSRC. The review of the EPSRC portfolio reveals that this proposal is distinct from previous and current research. The timeliness of the proposal is due to its building on the latest research of the three Universities, utilising current research from NPL into high-accuracy, flexible optical metrology and making use of state of the art vendor systems in large volume metrology. The combined effect of all these factors is that the underpinning knowledge, understanding and technologies required for this ambitious research are now in place, reducing research risk. Moreover, the project is timely in satisfying the industrial needs for better factory "ramp-up" flexibility and 100% product compliance with specifications at zero or minimum extra cost for high value products due to increasingly demanding customers and safety legislators. The Research Programme comprises five interrelated Research Topics (RTs) that will be carried out throughout the duration of the Grant. The RTs correspond to the research objectives and their work packages that include deliverables and milestones.

MRI scanners are used widely to diagnose disease and to understand the workings of the healthy body. However, while useful for some diagnoses, they do not capture tissue properties at microscopic length scales (thousandths of a millimetre) where important processes occur, e.g. in the 'axons' connecting different brain areas, or in cells in vital organs, e.g. liver. Such detailed examination usually requires an invasive 'biopsy' which is studied under a microscope. However, biopsies only provide information about small regions of an organ, are destructive and so cannot be performed repeatedly for monitoring, and can be risky to collect, e.g. in the brain. This project assembles engineers, physicists, mathematicians and computer scientists to develop new MRI methods for quantifying tissue structure at the microscopic scale. The principal approach looks at how fine tissue structure impedes the movement of water. Current MRI hardware restricts measurement to relatively large molecular displacements and from tissue components with a relatively strong and long-lived signal. This blurs our picture and prohibits us from quantifying important characteristics, such as individual cell dimensions, or packing of nerve fibres. The sensitivity of MRI to smaller molecular movements and weaker signals is mainly limited by the available magnetic field gradients (controlled alterations in the field strength within the scanner). We have persuaded MRI manufacturers to build a bespoke MRI system with ultra-strong gradients (7 times stronger than available on standard MRI scanners) to be situated in the new Cardiff University Brain Research Imaging Centre. One similar system currently exists (in Boston, USA) but is used predominantly to make qualitative pictures of the brain's wiring pattern. Our team has the unique combination of expertise to develop and exploit this hardware in completely new directions. By designing new physics methods to 'tune' the scanner to important (otherwise invisible) signals, developing new biophysical models to explain these signals, and suppressing unwanted signals, we will be able to quantify important tissue properties for the first time. Making such a system usable poses several key engineering challenges, such as modelling of electromagnetic fields, to deal with confounds that become significant with stronger gradients, and modelling of the effects on nerves/cardiac tissue, to impose safety constraints. However, the current work of the consortium of applicants provides strong starting points for overcoming these challenges. Established methods for accelerating MR data acquisition will be compromised with stronger gradients, requiring development of new physics methods for fast data collection. Once achieved, faster acquisition and access to newly-visible signal components will enable us to develop new mathematical models of microstructure incorporating finer length-scales to increase understanding of tissue structure in health and disease, and to make testable predictions on important biophysical parameters such as nerve conduction velocities in the brain. This will result in earlier and more accurate diagnoses, more specific and better-targeted therapy, improved treatment monitoring, and overall improved patient outcome. The ultimate goal is to develop the imaging software that brings this hardware to mass availability, in turn enabling a new generation of mainstream microstructure imaging and macrostructural connectivity mapping techniques to translate to frontline practice.

Manufacture Using Advanced Powder Processes - MAPP Conventional materials shaping and processing are hugely wasteful and energy intensive. Even with well-structured materials circulation strategies in place to recondition and recycle process scrap, the energy use, CO2 emitted and financial costs associated are ever more prohibitive and unacceptable. We can no longer accept the traditional paradigm of manufacturing where excess energy use and high levels of recycling / down cycling of expensive and resource intensive materials are viewed as inevitable and the norm and must move to a situation where 100% of the starting material is incorporated into engineering products with high confidence in the final critical properties. MAPP's vision is to deliver on the promise of powder-based manufacturing processes to provide low energy, low cost, and low waste high value manufacturing route and products to secure UK manufacturing productivity and growth. MAPP will deliver on the promise of advanced powder processing technologies through creation of new, connected, intelligent, cyber-physical manufacturing environments to achieve 'right first time' product manufacture. Achieving our vision and realising the potential of these technologies will enable us to meet our societal goals of reducing energy consumption, materials use, and CO2 emissions, and our economic goals of increasing productivity, rebalancing the UK's economy, and driving economic growth and wealth creation. We have developed a clear strategy with a collaborative and interdisciplinary research and innovation programme that focuses our collective efforts to deliver new understanding, actions and outcomes across the following themes: 1) Particulate science and innovation. Powders will become active and designed rather than passive elements in their processing. Control of surface state, surface chemistry, structure, bulk chemistry, morphologies and size will result in particles designed for process efficiency / reliability and product performance. Surface control will enable us to protect particles out of process and activate them within. Understanding the influence between particle attributes and processing will widen the limited palette of materials for both current and future manufacturing platforms. 2) Integrated process monitoring, modelling and control technologies. New approaches to powder processing will allow us to handle the inherent variability of particulates and their stochastic behaviours. Insights from advanced in-situ characterisation will enable the development of new monitoring technologies that assure quality, and coupled to modelling approaches allow optimisation and control. Data streaming and processing for adaptive and predictive real-time control will be integral in future manufacturing platforms increasing productivity and confidence. 3) Sustainable and future manufacturing technologies. Our approach will deliver certainty and integrity with final products at net or near net shape with reduced scrap, lower energy use, and lower CO2 emissions. Recoupling the materials science with the manufacturing science will allow us to realise the potential of current technologies and develop new home-grown manufacturing processes, to secure the prosperity of UK industry. MAPP's focused and collaborative research agenda covers emerging powder based manufacturing technologies: spark plasma sintering (SPS), freeze casting, inkjet printing, layer-by-layer manufacture, hot isostatic pressing (HIP), and laser, electron beam, and indirect additive manufacturing (AM). MAPP covers a wide range of engineering materials where powder processing has the clear potential to drive disruptive growth - including advanced ceramics, polymers, metals, with our initial applications in aerospace and energy sectors - but where common problems must be addressed.

The EPSRC Centre for Innovative Manufacturing in Additive Manufacturing will create a sustainable and multidisciplinary body of expertise that will act as a UK and international focus - the 'go to' place for additive manufacturing and its applications. The Centre will undertake a user-defined and user-driven programme of innovative research that underpins Additive Manufacturing as a sustainable and value-adding manufacturing process across multiple industry sectors.Additive Manufacturing (AM) is the direct production of end-use component parts made using additive layer manufacturing technologies. It enables the manufacture of geometrically complex, low to medium volume production components in a range of materials, with little, if any, fixed tooling or manual intervention beyond the initial product design. AM enables a number of value chain configurations, such as personalised component part manufacture but also economic low volume production within high cost base economies. This innovative approach to manufacturing is now being embraced globally across industry sectors from high value aerospace / automotive manufacture to the creative and digital industries. To date AM research has almost exclusively focused upon the production of single material, homogeneous structures (in polymers, metals and ceramics). The EPSRC Centre for Innovative Manufacturing in Additive Manufacturing will move away from single material, 'passive' AM processes and applications that exhibit conventional levels of functionality, toward the challenges of investigating next generation, multi-material active additive manufacturing processes, materials and design systems. This transformative approach is required for the production of the new generation of high-value, multi-functional products demanded by industry. The Centre will initially explore two themes as the centrepieces of a wider research portfolio, supported by a range of platform activities. The first theme takes on the challenge of how to design, integrate and effectively implement multi-material, multi-functional manufacturing systems capable of matching the requirements of industrial end-users for 'ready-assembled' multifunctional devices and structures. Working at the macro level, this will involve the convergence of several approaches to increase embedded value to the product during the manufacturing stage by the direct printing / deposition of electronic / optical tracks potentially on a voxel by voxel basis; the processing and bonding of dissimilar materials that ordinarily require processing at varying temperatures and conditions will be particularly challenging. The second theme will explore the potential for 'scaling down' AM for small, complex components, extending single material AM to the printing of optical / electronic pathways within micro-level products and with a vision to directly print electronics integrally. The platform activities will provide the opportunity to undertake both fundamental and industry driven pilot studies that both feed into and derive from the theme-based research, and grow the capacity and capability of the Centre, creating a truly national UK Centre and Network that maintains the UK at the front of international research and industrial exploitation in Additive Manufacturing.

Hybrid Manufacturing concerns digitally-driven and template-less manufacturing processes which are founded on cross-technology process platforms. Our group focuses on how truly transformative capability may be realised by the next generations of this ideology. Our Hybrid Manufacturing Process research is founded on the premise that future generations of products, with multi-faceted complexity and transformative capability may be realised through the combination of multiple process technologies within a singular platform, while incorporating emerging research from the physical sciences (such as functional materials). This aims to provide an exponential increase in the capability for complex manufacturing and the magnitude of resultant value. Our pioneering research has been recognised by a number of eminent parties and international peers. Our research group possess unique research capability, which is significantly due to the recruitment and development of a cohort of outstanding researchers and our suite of globally unique experimental manufacturing apparatus. The growth and momentum of our current activity, along with our pipeline of future research and innovation, now warrants a supporting platform in order to secure and maintain our world-leading position. It will enable us to stengthen our strategic approach to leading research, allow us to continue to shape and capitalise on emerging opportunities, and further develop the next generation of truly interdisciplinary research leaders. This will ensure that the UK remains at the forefront of this exciting and valuable field of manufacturing process research.