This project will establish a collaborative framework in which industry can access both High Performance Computing (HPC) facilities and industry standard commercial software packages in a commercially viable and sustainable manner. In particular, we will work with three software vendors (MathWorks, ESI and Wilde) to produce case studies demonstrating the competitive advantage to SMEs that can arise from access to quality software on HPC facilities. The project will also explore the options for more flexible licensing models that are consistent with HPC-on-demand, and will evaluate the scope for SMEs, particularly within the Engineering and Manufacturing sectors within the MidPlus region, to exploit HPC in improving their product design and development cycles.

This project focuses on the development of a manufacturing route for composite materials capable of producing complex components in a single process chain based on advancements in the knowledge, measurement and prediction of uncertainty in processing. The methodology proposed uses measurements of the instantaneous state of a component during production, predictive modelling of associated variability and numerical optimisation. These three are integrated in a control loop that allows the process to adapt in real time in order to compensate for deviations from its nominal state due to variability. This manufacturing philosophy accepts the existence of variability in these highly heterogeneous and directional materials and uses it in order to improve the product as the process evolves. The necessary developments comprise major manufacturing challenges, such as the real time measurement of fibre variability in robotic fibre placement and the processing of composite components involving areas of large thickness. These are accompanied by significant mathematical advancements, such as the numerical solution of coupled non-linear stochastic partial differential equations, the inverse estimation of composite properties and their probability distributions in different directions based on real time measurements and the formulation and solution of a stochastic model of the variability in fibre arrangements. The integration of these developments will be carried out on a single process chain of fibre placement, resin infusion and resin cure; however their applicability is generic in the context of manufacturing involving heterogeneous materials and variability. The outcome of this work will enable a step change in the capabilities of composite manufacturing technologies to be made, overcoming limitations related to part thickness, component robustness and manufacturability as part of a single process chain, whilst yielding significant developments in mathematics with generic application in the fields of stochastic modelling and inverse problems.

The aim of the this project is to introduce the concept of "small is beautiful" into a conservative relatively low technology manufacturing sector where the "economies of scale" argument has been used for the last decade to build ever more so-called efficient process lines. This will be a major challenge. The new philosophy, "small is beautiful", starts by encouraging the use of high quality feedstock, only melting what is required and only when it is required. Recycling of internal scrap is not necessarily acceptable but an aim for higher yields is. Applying counter gravity casting methods to improve yield and give enhanced quality is encouraged as is the recovery low grade heat from solidification. The project will achieve this by the development of a software tool incorporating a new philosophy/methodology and metric for the handling of materials and energy throughout the process in foundries using computer numerical process simulation to support the decision making. The project would also look at the full energy chain from charge materials through to waste heat and energy in the process and identify the opportunities for scavenging waste heat and the costs associated with the whole process. This will therefore enable cost/benefit analysis to be undertaken so that companies will be able to make informed decisions about design, material and process at a very early stage.

The Materials Made Smarter Centre has been co-created by Academia and Industry as a response to the pressing need to revolutionise the way we manufacture and value materials in our economy. The UK's ability to manufacture advanced materials underpins our ambitions to move towards cleaner growth and a more resource efficient economy. Innovation towards a net zero-carbon economy needs new materials with enhanced properties, performance and functionality and new processing technologies, with enhanced manufacturing capability, to make and deliver economic and societal benefit to the UK. However, significant technological challenges must still be overcome before we can benefit fully from the transformative technical and environmental benefits that new materials and manufacturing processes may bring. Our capacity to monitor and control material properties both during manufacture and through into service affect our ability to deliver a tailored and guaranteed performance that is 'right-first-time' and limit capacity to manage materials as assets through their lifetime. This reduces materials to the status of a commodity - a status which is both undeserved and unsustainable. Future materials intensive manufacturing needs to add greater value to the materials we use, be that through reduction of environmental impact, extension of product life or via enhanced functionality. Digitalisation of the materials thread will help to enhance their value by developing the tools and means to certify, monitor and control materials in-process and in-service improving productivity and stimulating new business models. Our vision is to put the UK's materials intensive manufacturing industries at the forefront of the UK's technological advancement and green recovery from the dual impacts of COVID and rapid environmental change. We will develop the advanced digital technologies and tools to enable the verification, validation, certification and traceability of materials manufacturing and work with partners to address the challenges of digital adoption. Digitisation of the materials thread will drive productivity improvements in materials intensive industries, realise new business models and change the way we value and use materials.