Factory for the future: ALT

Factory for the Future:Advanced Laser Technology

4th June 2015

Agenda

10:30: Welcome from Roger Hardacre, Managing Director ALT Ltd

10:40: Professor Lin Li, Fellow of RAE & Director of Laser Processing

Research Centre, School of Mechanical, Aerospace & Civil Engineering,

University of Manchester

11:00: Charlie Rea, Business Growth Manager, Business Growth

Service (MAS)

11:15: Valerie De Leonibus, Founder & Director, Inventya Ltd

11:30: Roger Hardacre, Sol Gel Project Case Study Presentation

12:00: Lunch & Networking

12:30: Close

Welcome

Roger Hardacre

Managing Director

Advanced Laser Technology Ltd

Professor Lin Li

Fellow of RAE & Director of Laser Processing Research Centre, School of Mechanical, Aerospace & Civil Engineering

University of Manchester

AILU: At the centre of the UK LMP community

Professor Lin Li, Vice President of AILU

Founded 1995

Independent, non-commercial, non-profit making

Driven by a fascination for lasers and their potential in manufacturing

Principal outputs:

• Active telephone and email assistance

• Quarterly magazine

• Monthly newsletter

• 4 technical workshops and one business meeting a year

• Active association website and Design for Laser Manufacture site

• Technical reports, ILAS conference every 2 years

Product & Service Directory

Magazine

Continues to be well received but could do better with:

•Suitable UK research papers

•Members’ news

E-Magazine

E-Newsletter

Continues to be well received.

Special thanks to Mike Barrett

AILU Web site

Open JS forum viewing to visitors

23000 visits/ year

D4LM Web site

7500 visits/ year



Corporate Member distribution 2015

Contact:

www.ailu.org.uk

[email protected]

Support for Manufacturers

Charlie Rea

04/06/2015

The Business Growth Service

The Business Growth Service brings together into a single service;

GrowthAccelerator

Manufacturing Advisory Service

Intellectual Property Office IP Audits

Design Council Design Mentoring

Export support is provided by UKTI and UKEF. The service is closely linked to InnovateUK and the British Business Bank.

Objective

To help you to achieve your potential by identifying barriers to growth and providing tailored support that fits your needs, including coaching, consultancy, mentoring, training, access to finance and export advice.

How is works

Identify your needsUndertake a business review

Identify barriers to growth

Opportunities to grow

Apply your strategyGrant support for in-depth project

Selection of an Expert if required

Hit your growth targetsMeasurement of the business benefits when the project is complete

How we can help your business to grow

Manufacturing Strategy

Manufacturing Innovation

Manufacturing Efficiency

Manufacturing Supply Chains

To plan your business

Manufacturing Strategy Business Strategy Sales Growth & Marketing Strategy Gross Margin & Overheads

Analysis Quality (ISO 9001), Environmental

(ISO14001) & appropriate sector standards

E-business strategy Establishing financial metrics,

controls and systems

To develop your new ideas

Materials and Product Innovation Product Idea Generation Intellectual Property Review Audits Design for Manufacture and

Assembly (DFMA) CAD CAM CAE (Computer Aided

Engineering) & Rapid Prototyping Product Conformance and

Compliance Testing to market requirements

Case Study 1. Fonebox

1. Fonebox

Customer Segments Mobile device users Public venues – bars, clubs, other public places Media agencies

Value Proposition Secure recharging of mobile devices Value-added service to venue clientele + revenue stream Targeted, location specific advertising medium

Business model provides options for leasing, purchase or free issue of unit

BGS support & results

Supported by BGS through: Innovation consultancy on NPD process, IP, business

strategy… Manufacturing Innovation product design grant

Supported in planning for Continental roll-out by UKTI

Sales turnover of c.£800k forecast for first 12 months

Case Study 2: Chameleon Studio

Who we are

Design Innovation, why and how

Case Studies

2. Chameleon Studio

Customer Segment Tattoo studios in UK, EU and USA seeking high-

performance and premium quality tattoo gun

Value Proposition Provides class-leading control, accuracy and reliability

through incorporation of high performance precision motor Design optimised for ease-of-use, comfort, function and

appearance The only Made in Britain product of its type

Supported by BGS Manufacturing Grant for Tooling Manufacture

Export drive into EU and USA supported by UKTI

Forecast to increase sales by £500k and create 2 new jobs

BGS support & results

Who we are

Design Innovation, why and how

Case Studies

Helping to improve your processes

Value Stream Mapping & Process Mapping

Team Building Improving layouts, Space Utilisation & Cellular manufacturing Improving Quality & Delivery 5S & Visual Management Six Sigma & Quality Improvement Overall Equipment Effectiveness

(OEE) Single Minute Exchange of Dies

(SMED)

Helping you grow your supply chain

Industry-specific supply chain programmes (eg SC21, TS16949, TS16949)

Reviewing your Supply Chain Strategy

Maximising Involvement in Existing Supply Chains

Getting into New Supply Chains Bringing some or all of your

Manufacturing back to the UK (reshoring)

Supplier selection and approval programme

Total cost of acquisition

Further support for High Growth companies

Business Development CoachingEquips participants to implement high growth strategies

Leadership & Management trainingImproves the skills and capabilities of managers

Access To FinanceImproves business investment readiness and ways to source / pitch for investment

Growth Through InnovationImproves internal capabilities for development of new product and market strategies

Intellectual Property AuditDesign Mentoring

Eligibility

To be eligible for Manufacturing support, your business must:

Meet the EU definition of an SMEHave fewer than 250 employeesHave a turnover of less than £40m

Be registered in the UK and based in England

Be a Manufacturer

Have growth potential

greatbusiness.gov.uk/mas

Thank You

Charlie Rea

[email protected]

M: 07702 277 907

mailto:[email protected]

© Copyright Inventya Limited - 2009

Bespoke Market Intelligence for Science and Technology

Co-Founder & Director, Inventya Ltd

Valerie De Leonibus

Advanced Laser Technology LtdFactory for the Future, Manchester 4 June 2015

Advanced Laser Technology Ltd.Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved

36

What we do• Bespoke global market research, testing, feasibility studies & validation• Commercial validation including evaluating IP position, freedom to operate & route to

market options• R&D grant writing for early stage firms – 85% success rate – including Innovate UK and

Horizon 2020• Commercialisation/exploitation partner in large collaborative European projects

INVENTYA OVERVIEW

Why it adds value• Life sciences sector - commercial viability research for a novel pediatric drug, subsequently

raising £500k from IUK and £2.6m VC funding for clinical trials • Rail engineering - market assessment and developed business case for a novel rail

technology, then secured £300k for R&D and commercialization• Aerospace – market assessment report validated demand, brokered Tier 1 carrier meeting

for client & found 5 partners for large collaborative R&D bid

Who we are• Science, engineering and technology commercialisation consultancy • Founded 2006, based at Sci-Tech Daresbury in Cheshire• Secured over £35m in R&D grant funding for clients• 20 staff with strong academic backgrounds in science, technology & business

Advanced Laser Technology Ltd.Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved

37

Phase 1

Phase 2

Phase 3

Phase 4

Identify Grants Available for clients

Grant Writing Process

Opportunities Identification

Technology/Product Info

• Determine Market Structure

• Competitor Analysis

• Establish drivers and barriers to commercialisation

Secondary Research Review

Questionnaire Review

• Primary Research using surveys, interviews and face to face discussion with stakeholders

Primary Review/ Secondary Review (if any)

• Business Model Canvas

• Exploitation and Commercialisation Plan

Contact with stakeholders

Findings Presentation

PoM Report

• Manager• Lead Consultant• Second

Consultant

• Lead Consultant• Second

Consultant

• Lead Consultant• Second

Consultant

• Manager• Lead Consultant• Second

Consultant

Inventya PROJECT Workflow

Advanced Laser Technology Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved 38

Relationship with ALT Ltd

Inventya helped secure >£120k in R&D funding to de-risk 5 innovative ideas for new services

Helped ALT to better understand their markets with trend and market size analysis using primary market research, specific

publications, official statistics and government reports, trade and industry publications

Conducted more than 50 global interviews with C-suite executives in aerospace, oil and gas, petrochemical and shipbuilding

industries, isolating key issues facing high value machinery and the efficacy of current anti-corrosion & anti-erosion solutions

Fed back knowledge gained from industry experts into ALT management team for enhancing their products/services and

communicating the right value propositions to target customer segments

With MAS, helped ALT to showcase their technologies and products to industry users

Facilitated discussions with the industry users of laser cladding products


Role in Sol Gel Project

Analyse market dynamics

Identified main leaders in precision engineering

Identified main communication channels

Approached manufacturing managers and designers with the sol gel research propositions

Fed back necessary knowledge gained from potential industry users to enhance the development of sol gel recipes

Exploitation and dissemination (marketing plan, introduction of research results to end users, optimise website material)


Work Process Flow

User CenteredApproach

Innovate

Understand Users

Funding/Investment

Feedback to refine the Value Propositions

Prototype

Design Analysis

Build

Validate

Implementation in External Environment

Market Research


Market Dynamics

• North America is the biggest market of laser cladding and technologies with the revenues of $160 million in 2012.

• Laser cladding is expected to dominate in North America in coming years from 2013-2018 with the compounded

annual growth rate (CAGR) of 8.7%.

• In Europe, Germany is one of the biggest market of laser cladding technologies and is expected to reach $110million

by 2018 from $84 million in 2013.

2011 2012 2013 20180

50

100

150

200

250

140 145 150

225

European market for laser cladding equipment ($ millions)

Mill

ion

(USD

)

2011 2012 2013 20180

100

200

300

400

500

600

700

800

450 470 490

705

Global market for laser cladding equipment ($millions)

Mill

ion

(USD

)

Source: BCC Research


Market Dynamics

• Aerospace industry is one of the main markets for laser cladding which will grow with a CAGR of 9.5% and its size will

reach to $110 million by 2018.

• Laser cladding in offshore oil drilling is expected to rise with a CAGR of 8.4% from 2013-2018 to reach a market size

of $90 million in 2018.

Application ($millions) 2011 2012 2013 2018CAGR %

(2013-2018)

Aerospace Industry 60 65 70 110 9.5

Offshore oil drilling 60 60 60 90 8.4

Miscellaneous applications 20 20 20 25 4.6

Total 140 145 150 225 8.4

European market of laser cladding in different industries.

Source: BCC Research


Stakeholders Feedback

Main issues with traditional surface coating technologies –

• When stakeholders were asked about current issues they are facing with their surface coating techniques most of them

identified problems arising from multiple processes involved, and the difficulty of cladding on complex surfaces

• They highlighted that numerous processes (at least 3-4) involved in treating high value machinery led to decreased productivity

• More than 70% respondents stated that during the complete surface coating process at least 10-30% of the total time is

consumed by machining and surface preparation

Sol gel most attractive elements

• Almost 60% of stakeholders highlighted as the key attractive elements of proposed sol gel solution:• “shorter processing time as compared to traditional coatings”, • “ease to clad complex geometries”, • “up to 100% utilisation (material efficiency) of sol gel material”

Roger Hardacre

Sol Gel Project Case Study Presentation

9 Piccadilly Trading Estate, Giddings Road, Manchester, United Kingdom, M1 2NPTel:+44(0)161 273 3880 Fax:+44(0)161 2738873 Email: [email protected]

Agenda

Lasers today

Growing importance of lasers in machine tool industry

Main applications of lasers

An example of how lasers are pushing the boundary.

Lasers: then and now

1996 machine4kW deliverable powerBig, expansive and immovable

With eight chillersInput energy: over 20kW

Now: look around our factory for modern versions: smaller, more efficient, portable

Lasers now firm part of machine tool industry:

2014 Global machine tool industry sales $77bn

2014 Global sales lasers $9.2bn – 12% of total

Growth driven by two types: diodes and fibres

Main driving markets for growth: engineering: automotive, aerospace, nuclear

Lasers have own “Moores Law” more power, lower cost, smaller size

Main Applications

Cladding: changing the nature of metal components.

Hardening: lower energy and precise hardening methods

Cleaning: blowing off debris without chemicals

Building: internal complexity without joints

Welding: thinner and thinner and reduced stress zones

Pushing the boundaries of Industrial Technology

Sol Gel: making its easier to produce hard wearing components

•It is considered as a new industrial technology.

Sol –gel (what it is?)

•It is a chemical route to the manufacture of ceramics and inorganic-organic hybrid materials.

•The term sol-gel refers to a process in which solid nanoparticles dispersed in a liquid (a sol) agglomerate together to form a continuous three-dimensional network extending throughout the liquid (a gel).

Innovatory project Part funded by InnovateUK

ObjectivesTo develop a laser applied surface cladding technique using a Sol Gel

Will help to decrease the manufacturing process to one stage as compared to traditional laser cladding technique.

The process can be applied to a number of parts without impacting on their dimensions.

It can be applied to complex shapes and vertical surfaces without extra consideration of planning and manufacturing times.

A. Synthesis of a variety of shapes by Sol Gel

Sol-gels can be processed before gelation by a range of methods including spraying to produce coatings and powders, drawing from a liquid to produce fibres and processing in a vessel to produce aerogels and monoliths.

PowdersSol

(Stable suspension)

Precursor solution(metal alkoxide)

Dense monoliths

(Solvent evaporation then

fire

Gel (Solid network supporting solvent)

Fibers(drawn from the gel or spun)

Aerogels(supercritical

solvent extraction)

Nanostructure materials(gelation with

templates)

Films(gelation as solvent

evaporates)

B. Sol-Gel applicability

Sol-gelTechnology Applications

Thin films

Fib

ersPow

der

s

Composites

Functional Thin films

Nan

o-p

arti

cles

Nanostructures

Rein

forcing fib

ers

Ch

emic

al

tech

nol

ogy

Bu

ildin

g /constru

ction

ind

ustry

Biomedical technology

Solar Technology

C. Achieved properties by Sol-Gel

Hydrophobic surfaces.

Anti-fingerprinting.

Anti-microbial surfaces.

Easy to clean surfaces.

Protective transparent coatings.

UV protection.

Higher mechanical wear resistant properties.

Low friction.

Corrosion resistance.

Antistatic surfaces.

Conducting/semi-conducting surfaces.

Economic

• Compared to traditional laser cladding techniques includes. • Shorter processing

times.• and the more efficient

use of coatings (Up to 100% applied)

• No post treatment after processing.• Grinding. • Machining .

•

Social

• Manufacture and remanufacture with less materials are longer lasting.

• Cheaper and therefore better value products.

• Less money spent on waste disposal.

• With more manufacturing capabilities comes more consumer choice especially for those products with greater sustainability and conservation of resources, and provides more awareness of these issues.

• More innovation in processing methods :• Encourages more

manufacturing applications

• The creation of new skills.

Environmental • Less manufacturing time, especially machining, so• Energy costs are

lowered• carbon emissions in

producing this energy are reduced

• Use of a thin material means less waste is created that can damage the environment through infill sites and incineration releasing more pollution into the environment

• This reduces damage to ecosystems and other environmental processes helping to protect the natural environment

Project benefits

Apply a spray coating

Experimental procedures

Energy (W)Max 4 KW Laser energy

Protection To assure the adhesion to the substrate

Hard surface

(Gas protector)Preference for compressed air

air for the recipe (Scanning speed mm/s)

Sand blasted surfaceCleaned with ethanolDried (hot air)

Bonding quality can meet most of industrial requirement

Cast iron

Experimental results (surface morphology)

Mild steel (thick film)

Today we have representatives from three of the world’s leading laser suppliers, and our own engineers.

Your use of lasers in the future is dependent on your development skills.

Consider lasers whenever you are bidding or developing new applications.

Thank You

Graphene Industry Workshops 2015

22nd June, 9:00am – 1:30pm, National Graphene Institute,

The University of Manchester

(for business support organisations)

24th June, 9:00am – 4:45pm, National Graphene Institute,


(for manufacturing organisations – Electronic Devices)

25th June, 9:00am – 4:45pm, National Graphene Institute,


(for manufacturing organisations – Composites & Coatings)

To book a place contact [email protected]

Lunch & Networking