Materials Processing Institute

The Materials Processing Institute is leading a £600,000 research collaboration to develop a groundbreaking artificial intelligence tool capable of creating greater efficiencies within the Additive Manufacturing (AM) sector.

Working in partnership with Additive Manufacturing Solutions Ltd and AMFG, it aims to provide a versatile, commercial, predictive material reuse management tool that will enable AM to expand by introducing greater cost efficiencies.

Known as SMART-APP, its aim is to enable world class production of AM components, using Laser Powder Bed Fusion through the introduction of smart predictive models for resource efficiency and waste reduction.

SMART-APP aims to predict the quality change of the powder after each process and propose alternative process parameters on used powder to extend its lifespan with a minimal or an in-specification impact on product quality.

The project is funded by Innovate UK, part of UK Research and Innovation (UKRI), the UK’s innovation agency, which drives productivity and economic growth by supporting businesses to develop and realise the potential of new ideas.

One area of particular interest is the growth of metal AM which is not yet cost-effective due to a development gap in the level of powder waste and length of processing time.

The research will feature state-of-the-art materials characterisation, and mechanical testing, investigating shelf life and the processability envelope of environmentally affected common stainless steel, titanium and superalloy base feedstock. It will also examine methods of reclaiming the powders and the effect on the final product.

The resulting outputs will be fed into an advanced database linking powder input properties against AM part performance to provide a predictive tool that will be available for industry to use.

Nick Parry, Industrial Digitalisation Group Manager at the Teesside-based Materials Processing Institute, said: “SMART-APP is the next logical step to continue the work the Institute has already undertaken in powder characterisation. By developing an artificial intelligence tool that can help AM users create faster and cheaper ways of maximising powder reuse, the AM industry, especially those needing to maximise the operational effectiveness of their machines.

“This predictive tool will develop and enable world class production of AM components, with smart solutions for resource efficiency and providing longer use of materials feedstock and reducing wastage.”

Rob Higham, CEO of Additive Manufacturing Solutions, added: “AMS is delighted to have the support of Innovate UK to continue developing our portfolio of world leading powder and AM process optimisation capability.

“This marks our first step towards a ground-breaking approach for dynamic materials management. The potential of the AM process remains a potential in many people’s eyes. It could be realised with the development of a versatile and smart predictive tool for tracking powder quality after each reuse.”

Alexander Grimmer, Technical Consultant at London-headquartered AMFG, a market-leading software company providing MES and workflow automation for manufacturing, said: “This initiative aims to transform additive manufacturing towards more resource-efficient methods.

“SMART-APP aims to instil trust in the additive manufacturing realm by forecasting powder quality and recommending processes to restore desired powder properties for reuse. AMFG eagerly anticipates contributing to a cutting-edge material management system in this project, poised to deliver substantial environmental and economic benefits to the industry. This endeavour is set to expedite the widespread adoption of additive manufacturing.”

ENDS

ISSSUED ON BEHALF OF MATERIALS PROCESSING INSTITUTE

MEDIA CONTACT: Andrew Douglas 01325 363 436

Photo caption: Powder assessment is carried out using morphological analysis at the Institute

Notes to editors:

Materials Processing Institute

The Materials Processing Institute is a research and innovation centre serving global steel and materials organisations that work in advanced materials, industrial decarbonisation, the circular economy, and digital technologies.

The Institute has served as the UK’s national steel innovation centre since 1944 having been set up by Sir Winston Churchill’s wartime government just before D-Day to equip the British steel industry for post-war reconstruction. It will celebrate its 80^th anniversary in 2024.

Through collaboration with its customers, the Institute provides a range of technology and R&D based services and consultancy. It also has pilot and demonstration facilities and an SME Technology Centre to support supply chain businesses with the development of new technologies and products.

Works with: steel, metals and alloys, chemical processes, aerospace and defence, energy, mining and quarrying, construction, rail, transport, and infrastructure, offshore, subsea, and nuclear.

https://www.mpiuk.com/

Additive Manufacturing Solutions Ltd

Established in 2017 by Robert Higham, AMS is a UK based but internationally connected and operational organisation. AMS offer support with AM strategic leadership, training, material & process validation, test and specification authoring alongside developing innovative and sustainable powder solutions.

https://www.additive-manufacturing.co.uk/

AMFG

AMFG is a leading provider of MES software for manufacturing. Our software solutions empower manufacturers to manage their unique workflows and achieve streamlined, automated processes. With over 500 successful implementations in over 35 countries and across a range of industries, we specialise in enabling companies to successfully integrate AM into their wider manufacturing processes and scale their AM operations.

https://amfg.ai/

Innovate UK

Innovate UK, part of UK Research and Innovation, is creating a better future by inspiring, involving and investing in businesses developing life-changing innovations.

We provide targeted sectors with expertise, facilities and funding to test, demonstrate and evolve their ideas, driving UK productivity and economic growth. Join our network and communities of innovators to realise the potential of your ideas and accelerate business growth. Innovate UK: inspiring business innovation.

https://www.ukri.org/councils/innovate-uk/