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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
AILU: At the centre of the UK LMP community
AILU: At the centre of the UK LMP community
Corporate Member distribution 2015
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
© 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
Advanced Laser Technology Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved 39
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)
Advanced Laser Technology Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved 40
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
Advanced Laser Technology Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved 41
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
Advanced Laser Technology Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved 42
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
Advanced Laser Technology Commercial in Confidence © Copyright Inventya Limited 2015 All Rights Reserved 43
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,
The University of Manchester
(for manufacturing organisations – Electronic Devices)
25th June, 9:00am – 4:45pm, National Graphene Institute,
The University of Manchester
(for manufacturing organisations – Composites & Coatings)
To book a place contact [email protected]
Lunch & Networking