̽��ֱ�� of Cambridge - manufacturing

Using lasers to ‘heat and beat’ 3D-printed steel could help reduce costs

sc604 — Mon, 30 Oct 2023 09:01:39 +0000

̽��ֱ��method, developed by a research team led by the ̽��ֱ�� of Cambridge, allows structural modifications to be ‘programmed’ into metal alloys during 3D printing, fine-tuning their properties without the ‘heating and beating’ process that’s been in use for thousands of years.

̽��ֱ��new 3D printing method combines the best qualities of both worlds: the complex shapes that 3D printing makes possible, and the ability to engineer the structure and properties of metals that traditional methods allow. ̽��ֱ��results are reported in the journal Nature Communications.

3D printing has several advantages over other manufacturing methods. For example, it’s far easier to produce intricate shapes using 3D printing, and it uses far less material than traditional metal manufacturing methods, making it a more efficient process. However, it also has significant drawbacks.

“There’s a lot of promise around 3D printing, but it’s still not in wide use in industry, mostly because of high production costs,” said Dr Matteo Seita from Cambridge’s Department of Engineering, who led the research. “One of the main drivers of these costs is the amount of tweaking that materials need after production.”

Since the Bronze Age, metal parts have been made through a process of heating and beating. This approach, where the material is hardened with a hammer and softened by fire, allows the maker to form the metal into the desired shape and at the same time impart physical properties such as flexibility or strength.

“ ̽��ֱ��reason why heating and beating is so effective is because it changes the internal structure of the material, allowing control over its properties,” said Seita. “That’s why it’s still in use after thousands of years.”

One of the major downsides of current 3D printing techniques is an inability to control the internal structure in the same way, which is why so much post-production alteration is required. “We’re trying to come up with ways to restore some of that structural engineering capability without the need for heating and beating, which would in turn help reduce costs,” said Seita. “If you can control the properties you want in metals, you can leverage the greener aspects of 3D printing.”

Working with colleagues in Singapore, Switzerland, Finland and Australia, Seita developed a new ‘recipe’ for 3D-printed metal that allows a high degree of control over the internal structure of the material as it is being melted by a laser.

By controlling the way that the material solidifies after melting, and the amount of heat that is generated during the process, the researchers can programme the properties of the end material. Normally, metals are designed to be strong and tough, so that they are safe to use in structural applications. 3D-printed metals are inherently strong, but also brittle.

̽��ֱ��strategy the researchers developed gives full control over both strength and toughness, by triggering a controlled reconfiguration of the microstructure when the 3D-printed metal part is placed in a furnace at relatively low temperature. Their method uses conventional laser-based 3D printing technologies, but with a small tweak to the process.

“We found that the laser can be used as a ‘microscopic hammer’ to harden the metal during 3D printing,” said Seita. “However, melting the metal a second time with the same laser relaxes the metal’s structure, allowing the structural reconfiguration to take place when the part is placed in the furnace.”

Their 3D printed steel, which was designed theoretically and validated experimentally, was made with alternating regions of strong and tough material, making its performance comparable to steel that’s been made through heating and beating.

“We think this method could help reduce the costs of metal 3D printing, which could in turn improve the sustainability of the metal manufacturing industry,” said Seita. “In the near future, we also hope to be able to bypass the low-temperature treatment in the furnace, further reducing the number of steps required before using 3D printed parts in engineering applications.”

̽��ֱ��team included researchers from Nanyang Technological ̽��ֱ��, the Agency for Science, Technology and Research (A*STAR), the Paul Scherrer Institute, VTT Technical Research Centre of Finland, and the Australian Nuclear Science & Technology Organisation. Matteo Seita is a Fellow of St John’s College, Cambridge.

Reference:
Shubo Gao et al. ‘Additive manufacturing of alloys with programmable microstructure and properties.’ Nature Communications (2023). DOI: 10.1038/s41467-023-42326-y

Researchers have developed a new method for 3D printing metal that could help reduce costs and make more efficient use of resources.

This method could help reduce the costs of metal 3D printing, which could in turn improve the sustainability of the metal manufacturing industry

Matteo Seita

Jude E. Fronda

Retrieval of a stainless steel part made by 3D printing

̽��ֱ��text in this work is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License. Images, including our videos, are Copyright © ̽��ֱ�� of Cambridge and licensors/contributors as identified. All rights reserved. We make our image and video content available in a number of ways – as here, on our main website under its Terms and conditions, and on a range of channels including social media that permit your use and sharing of our content under their respective Terms.

Yes

It’s high time for alliances to ensure supply chain security, researchers urge

sc604 — Thu, 19 Oct 2023 18:00:00 +0000

An international team of researchers, including from the ̽��ֱ�� of Cambridge, are calling on government agencies and national banks to support an effort to map the billions of connections in the global supply network which, among other impacts, could reduce tax evasion by as much as €130 billion (about £113 billion) annually in the European Union.

̽��ֱ��researchers say that understanding supply networks could also improve supply security, promote objective monitoring of the green transition, and strengthen human rights compliance. Writing in the journal Science, they emphasise that international alliances, backed by government organisations and the research community, are needed for such an understanding.

Even though most companies know their immediate trading partners, they depend on countless other relationships up and down the supply chain. A shortage anywhere in the supply network may aﬀect suppliers, suppliers of suppliers, and so on, as well as customers and their customers’ customers.

“Supply disruptions caused an estimated loss of 2% of global GDP in 2021 – approximately $1.9 trillion (£1.6 trillion) – and signiﬁcantly contributed to the current high inﬂation,” said lead author Anton Pichler from the Complexity Science Hub (CSH) in Vienna. “For a long time, it was unthinkable to analyse the global economy at the company level, let alone its complex network of supply interconnections. That is changing now.”

“Understanding supply chain interdependencies between companies, sectors, and countries is vital for many challenges, from identifying how disruptions may emerge and cascade across economies, through to monitoring carbon emissions and ensuring ethical and sustainable practice,” said co-author Professor Alexandra Brintrup from Cambridge’s Institute for Manufacturing.

For almost a century, only aggregated data – such as the average values of entire sectors – could be analysed. Predicting how individual company failures would aﬀect the system was simply not possible. What happens to the economy when a speciﬁc company stops its production? What if an earthquake paralyses an entire region?

“Now, a combination of new micro-datasets, methods based in machine learning, and multiple government initiatives are creating the ability to map entire economies, which can give us the tools to answer some fundamental questions with real and timely impact,” said Brintrup.

Although the volume of data is vast – there are approximately 300 million companies worldwide, each with an average of 40 domestic suppliers, resulting in up to 13 billion supply connections – researchers can map the connections between individual companies.

Currently, value-added tax (VAT) data is the most promising option for reconstructing reliable large-scale supply networks. Countries including Spain, Hungary and Belgium use a standardised VAT collection that practically records all domestic business-to-business (b2b) transactions. With these, it’s possible to map the entire national trade of a country.

In most countries like Germany, Austria, or France, where VAT is not collected for individual b2b transactions but only accumulated over a speciﬁc period, such mapping is not possible.

“ ̽��ֱ��standardised b2b collection could reduce administrative overheads for companies and would contribute substantially to tax compliance,” said co-author Christian Diem, also from CSH. Estimates suggest that VAT-related fraudulent activities in the European Union (EU) amount to €130 billion annually.

Beyond tax evasion, other global challenges also depend on the detailed knowledge of supply networks. “For individual companies, it’s nearly impossible to ensure that all trading partners, their suppliers, and their suppliers’ suppliers operate in an environmentally friendly way and in compliance with human rights,” said Pichler. “If this were centrally documented in a gigantic network, it could be more easily ensured.”

̽��ֱ��next step is to link trade data from diﬀerent countries. Currently, the EU records trade in goods between its member states at the company level. If it also included services and linked them with VAT data, this could lead to a comprehensive cross-border company-level network. According to the authors, this would represent almost 20% of the global GDP.

̽��ֱ��European Commission laid the legal foundation by proposing ‘VAT in the Digital Age.’ “Unfortunately, this is far from being realised,” said co-author Stefan Thurner, of the Complexity Science Hub. “So far, we do not have a single situation where the supply chain networks of any two countries have been joined and merged. This would be an essential next step.”

To create a truly international picture of supply interconnections, hundreds of datasets must be joined, analytical tools developed, and an institutional framework must be created, together with secure infrastructure for storing and processing enormous amounts of sensitive data.

“To advance this endeavour, a strong international alliance of various interest groups is required, including national governments, statistical oﬃces, international organisations, central banks, the private sector, and academia,” said Thurner. ̽��ֱ��ﬁrst collaboration in science, involving authors in macroeconomics, supply chain research, and statistics, now aims to establish a foundation. ̽��ֱ��researchers hope to inspire others to join their eﬀorts.

̽��ֱ��researchers hosted representatives of European ministries, national banks, statistical oﬃces, and researchers at a workshop in Vienna on 5–6 June 2023.

Reference:
Anton Pichler et al. ‘Building an alliance to map global supply networks.’ Science (2023). DOI: 10.1126/science.adi7521

Adapted from a CSH press release.

̽��ֱ��COVID-19 pandemic highlighted the interconnected nature of global supply chains, and showed how a disruption in one part of the world can have global effects. In 2021, supply disruptions were cost the global economy an estimated $1.9 trillion.

Understanding supply chain interdependencies between companies, sectors, and countries is vital for many challenges

Alexandra Brintrup

Abstract Aerial Art via Getty Images

Aerial shot of parked trucks, Scunthorpe, United Kingdom

Yes

Robots cause company profits to fall – at least at first

sc604 — Thu, 03 Aug 2023 10:05:12 +0000

̽��ֱ��researchers, from the ̽��ֱ�� of Cambridge, studied industry data from the UK and 24 other European countries between 1995 and 2017, and found that at low levels of adoption, robots have a negative effect on profit margins. But at higher levels of adoption, robots can help increase profits.

According to the researchers, this U-shaped phenomenon is due to the relationship between reducing costs, developing new processes and innovating new products. While many companies first adopt robotic technologies to decrease costs, this ‘process innovation’ can be easily copied by competitors, so at low levels of robot adoption, companies are focused on their competitors rather than on developing new products. However, as levels of adoption increase and robots are fully integrated into a company’s processes, the technologies can be used to increase revenue by innovating new products.

In other words, firms using robots are likely to focus initially on streamlining their processes before shifting their emphasis to product innovation, which gives them greater market power via the ability to differentiate from their competitors. ̽��ֱ��results are reported in the journal IEEE Transactions on Engineering Management.

Robots have been widely used in industry since the 1980s, especially in sectors where they can carry out physically demanding, repetitive tasks, such as automotive assembly. In the decades since, the rate of robot adoption has increased dramatically and consistently worldwide, and the development of precise, electrically controlled robots makes them particularly useful for high-value manufacturing applications requiring greater precision, such as electronics.

While robots have been shown to reliably raise labour productivity at an industry or country level, what has been less studied is how robots affect profit margins at a similar macro scale.

“If you look at how the introduction of computers affected productivity, you actually see a slowdown in productivity growth in the 1970s and early 1980s, before productivity starts to rise again, which it did until the financial crisis of 2008,” said co-author Professor Chander Velu from Cambridge’s Institute for Manufacturing. “It’s interesting that a tool meant to increase productivity had the opposite effect, at least at first. We wanted to know whether there is a similar pattern with robotics.”

“We wanted to know whether companies were using robots to improve processes within the firm, rather than improve the whole business model,” said co-author Dr Philip Chen. “Profit margin can be a useful way to analyse this.”

̽��ֱ��researchers examined industry-level data for 25 EU countries (including the UK, which was a member at the time) between 1995 and 2017. While the data did not drill down to the level of individual companies, the researchers were able to look at whole sectors, primarily in manufacturing where robots are commonly used.

̽��ֱ��researchers then obtained robotics data from the International Federation of Robotics (IFR) database. By comparing the two sets of data, they were able to analyse the effect of robotics on profit margins at a country level.

“Intuitively, we thought that more robotic technologies would lead to higher profit margins, but the fact that we see this U-shaped curve instead was surprising,” said Chen.

“Initially, firms are adopting robots to create a competitive advantage by lowering costs,” said Velu. “But process innovation is cheap to copy, and competitors will also adopt robots if it helps them make their products more cheaply. This then starts to squeeze margins and reduce profit margin.”

̽��ֱ��researchers then carried out a series of interviews with an American medical equipment manufacturer to study their experiences with robot adoption.

“We found that it’s not easy to adopt robotics into a business – it costs a lot of money to streamline and automate processes,” said Chen.

“When you start bringing more and more robots into your process, eventually you reach a point where your whole process needs to be redesigned from the bottom up,” said Velu. “It’s important that companies develop new processes at the same time as they’re incorporating robots, otherwise they will reach this same pinch point.”

̽��ֱ��researchers say that if companies want to reach the profitable side of the U-shaped curve more quickly, it’s important that the business model is adapted concurrently with robot adoption. Only after robots are fully integrated into the business model can companies fully use the power of robotics to develop new products, driving profits.

A related piece of work being led by the Institute for Manufacturing is a community programme to help small- and medium-sized enterprises (SMEEs) to adopt digital technologies including robotics in a low-cost, low-risk way. “Incremental and step changes in this area enable SMEs to get the benefits of cost reduction as well as margin improvements from new products,” said co-author Professor Duncan McFarlane.

̽��ֱ��research was supported by the Engineering and Physical Sciences Research Council (EPSRC) and the Economic and Social Research Council (ESRC), which are both part of UK Research and Innovation (UKRI). Chander Velu is a Fellow of Selwyn College, Cambridge. Duncan McFarlane is a Fellow of St John's College, Cambridge.

Reference:
Yifeng P Chen, Chander Velu, Duncan McFarlane. ‘ ̽��ֱ��Effect of Robot Adoption on Profit Margins.’ IEEE Transactions on Engineering Management (2023). DOI: 10.1109/TEM.2023.3260734

Researchers have found that robots can have a ‘U-shaped’ effect on profits: causing profit margins to fall at first, before eventually rising again.

It’s important that companies develop new processes at the same time as they’re incorporating robots, otherwise they will reach this same pinch point

Chander Velu

kynny via Getty Images

Robots on a manufacturing line

Yes

Cambridge researchers help develop smart, 3D printed concrete wall for National Highways project

sc604 — Thu, 13 Jul 2023 12:01:02 +0000

̽��ֱ��3D-printed structure – a type of retaining wall known as a headwall – has been installed on the A30 in Cornwall, where it is providing real-time information thanks to Cambridge-designed sensors embedded in its structure. ̽��ֱ��sensors provide up-to-date measurements including temperature, strain and pressure. This ‘digital twin’ of the wall could help spot and correct faults before they occur.

Headwall structures are normally made in limited shapes from precast concrete, requiring formwork and extensive steel reinforcement. But by using 3D printing, the team – including specialists from Costain, Jacobs and Versarien – could design and construct a curved hollow wall with no formwork and no steel reinforcement. ̽��ֱ��wall gets its strength not from steel, but from geometry instead.

̽��ֱ��wall – which took one hour to print – is roughly two metres high and three and a half metres across. It was printed in Gloucestershire at the headquarters of the advanced engineering company Versarien, using a robot arm-based concrete printer. Making the wall using 3D printing significantly saves on costs, materials and carbon emissions.

Over the past six years, Professor Abir Al-Tabbaa’s team in the Department of Engineering has been developing new sensor technologies and exploring the effectiveness of existing commercial sensors to get better-quality information out of infrastructure. Her team has also developed various ‘smart’ self-healing concretes. For this project, they supplied sensors to measure temperature during the printing process.

Temperature variations at different layers of the 3D-printed wall were continuously monitored to detect any potential hotspots, thermal gradients, or anomalies. ̽��ֱ��temperature data will be correlated with the corresponding thermal imaging profile to understand the thermal behaviour of the 3D-printed wall.

“Since you need an extremely fast-setting cement for 3D printing, it also generates an enormous amount of heat,” said Al-Tabbaa. “We embedded our sensors in the wall to measure temperature during construction, and now we’re getting data from them while the wall is on site.”

In addition to temperature, the sensors measure relative humidity, pressure, strain, electrical resistivity, and electrochemical potential. ̽��ֱ��measurements provide valuable insights into the reliability, robustness, accuracy, and longevity of the sensors.

A LiDAR system also was used to scan the wall as it was being printed to create a 3D point cloud and generate a digital twin of the wall.

“Making the wall digital means it can speak for itself,” said Al-Tabbaa. “And we can use our sensors to understand these 3D printed structures better and accelerate their acceptance in industry.”

̽��ֱ��Cambridge team developed a type of sensor, known as a PZT (Piezoceramic Lead-Zirconate-Titanate) sensor, which measures electromechanical impedance response and monitors changes in these measurements over time to detect any possible damage. These smart sensors can show how 3D-printed mortar hardens over time, while simultaneously monitoring the host structure’s health.

Eight PZT sensors were embedded within the wall layers at different positions during the 3D printing process to capture the presence of loading and strain, both during the construction process and service life after field installation.

̽��ֱ��team, which included experts in smart materials, automation and robotics and data science, also developed a bespoke wireless data acquisition system. This enabled the collection of the multifrequency electromechanical response data of the embedded sensors remotely from Cambridge.

“This project will serve as a living laboratory, generating valuable data over its lifespan,” said Al-Tabbaa. “ ̽��ֱ��sensor data and ‘digital twin’ will help infrastructure professionals better understand how 3D printing can be used and tailored to print larger and more complex cement-based materials for the strategic road network.”

Members of the team included Dr Sripriya Rengaraju, Dr Christos Vlachakis, Dr Yen-Fang Su, Dr Damian Palin, Dr Hussam Taha, Dr Richard Anvo and Dr Lilia Potseluyko from Cambridge; as well as Costain’s Head of Materials Bhavika Ramrakhyani, a part-time PhD student in the Department of Engineering, and Ben Harries, Architectural Innovation Lead at Versarien, who is also starting a part-time PhD in the Department of Engineering in October.

̽��ֱ��Cambridge team’s work is part of the Resilient Materials for Life Programme and the Digital Roads of the Future Initiative. ̽��ֱ��research is supported in part by the Engineering and Physical Sciences Research Council (EPSRC), part of UK Research and Innovation (UKRI), and the European Union.

Cambridge researchers, working in partnership with industry, have helped develop the first 3D-printed piece of concrete infrastructure to be used on a National Highways project.

Making the wall digital means it can speak for itself, and we can use our sensors to understand these 3D-printed structures better and accelerate their acceptance in industry

Abir Al-Tabbaa

Cool Concrete – the smart, 3D printed concrete wall used for National Highways project.

National Highways

3D printed retaining wall

Yes

Changing how we talk — and think — about manufacturing

sc604 — Tue, 17 Jan 2023 15:50:09 +0000

Professor Tim Minshall, Head of Cambridge's Institute for Manufacturing, says it's time for a change in how we talk about manufacturing in the UK - and that means we must change how we think about it as well.

Students help to turn 100-year-old bakery into thriving online business

lw355 — Wed, 03 Aug 2022 08:03:53 +0000

Despite a few challenging years as a result of COVID-19, legendary Cambridge bakery Fitzbillies has emerged triumphant, with the help and insights of a group of students from Cambridge’s Institute for Manufacturing.

Digital manufacturing on a shoestring

lw355 — Thu, 24 Feb 2022 08:30:57 +0000

How approaches to low-cost digitalisation pioneered by Cambridge researchers are helping smaller UK manufacturers to go digital and reap the rewards of the Fourth Industrial Revolution.

Globalised economy making water, energy and land insecurity worse: study

sc604 — Mon, 26 Oct 2020 00:54:35 +0000

Countries meet their needs for goods and services through domestic production and international trade. As a result, countries place pressures on natural resources both within and beyond their borders.

Researchers from the ̽��ֱ�� of Cambridge used macroeconomic data to quantify these pressures. They found that the vast majority of countries and industrial sectors are highly exposed both directly, via domestic production, and indirectly, via imports, to over-exploited and insecure water, energy and land resources. However, the researchers found that the greatest resource risk is due to international trade, mainly from remote countries.

̽��ֱ��researchers are calling for an urgent enquiry into the scale and source of consumed goods and services, both in individual countries and globally, as economies seek to rebuild in the wake of COVID-19. Their study, published in the journal Global Environmental Change, also invites critical reflection on whether globalisation is compatible with achieving sustainable and resilient supply chains.

Over the past several decades, the worldwide economy has become highly interconnected through globalisation: it is now not uncommon for each component of a particular product to originate from a different country. Globalisation allows companies to make their products almost anywhere in the world in order to keep costs down.

Many mainstream economists argue this offers countries a source of competitive advantage and growth potential. However, many nations impose demands on already stressed resources in other countries in order to satisfy their own high levels of consumption.

This interconnectedness also increases the amount of risk at each step of a global supply chain. For example, the UK imports 50% of its food. A drought, flood or other severe weather event in another country puts these food imports at risk.

Now, the researchers have quantified the global water, land and energy use of 189 countries and shown that countries which are highly dependent on trade are potentially more at risk from resource insecurity, especially as climate change continues to accelerate and severe weather events such as droughts and floods become more common.

“There has been plenty of research comparing countries in terms of their water, energy and land footprints, but what hasn’t been studied is the scale and source of their risks,” said Dr Oliver Taherzadeh, who led the research while a PhD student in Cambridge’s Department of Geography. “We found that the role of trade has been massively underplayed as a source of resource insecurity – it’s actually a bigger source of risk than domestic production.”

To date, resource use studies have been limited to certain regions or sectors, which prevents a systematic overview of resource pressures and their source. This study offers a flexible approach to examining pressures across the system at various geographical and sectoral scales.

“This type of analysis hasn’t been carried out for a large number of countries before,” said Taherzadeh. “By quantifying the pressures that our consumption places on water, energy and land resources in far-off corners of the world, we can also determine how much risk is built into our interconnected world.”

̽��ֱ��authors of the study linked indices designed to capture insecure water, energy, and land resource use, to a global trade model in order to examine the scale and sources of national resource insecurity from domestic production and imports.

Countries with large economies, such as the US, China and Japan, are highly exposed to water shortages outside their borders due to their volume of international trade. However, many countries in sub-Saharan Africa, such as Kenya, actually face far less risk as they are not as heavily networked in the global economy and are relatively self-sufficient in food production.

In addition to country-level data, the researchers also examined the risks associated with specific sectors. Surprisingly, one of the sectors identified in Taherzadeh’s wider research that had the most high risk water and land use – among the top 1% of nearly 15,000 sectors analysed – was dog and cat food manufacturing in the USA, due to its high demand for animal products.

“COVID-19 has shown just how poorly-prepared governments and businesses are for a global crisis,” said Taherzadeh. “But however bad the direct and indirect consequences of COVID-19 have been, climate breakdown, biodiversity collapse and resource insecurity are far less predictable problems to manage – and the potential consequences are far more severe. If the ‘green economic recovery’ is to respond to these challenges, we need radically rethink the scale and source of consumption.”

Reference:
Oliver Taherzadeh et al. ‘Water, energy and land insecurity in global supply chains.’ Global Environmental Change (2020). DOI: 10.1016/j.gloenvcha.2020.102158

̽��ֱ��first large-scale study of the risks that countries face from dependence on water, energy and land resources has found that globalisation may be decreasing, rather than increasing, the security of global supply chains.

By quantifying the pressures that our consumption places on water, energy and land resources in far-off corners of the world, we can also determine how much risk is built into our interconnected world

Oliver Taherzadeh

WxMom

Iowa County Drought

̽��ֱ��text in this work is licensed under a Creative Commons Attribution 4.0 International License. Images, including our videos, are Copyright © ̽��ֱ�� of Cambridge and licensors/contributors as identified. All rights reserved. We make our image and video content available in a number of ways – as here, on our main website under its Terms and conditions, and on a range of channels including social media that permit your use and sharing of our content under their respective Terms.

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