Laser-based Manufacturing Applications · 2015-06-22 · Laser-based Manufacturing Applications UK Roadmap-2014 Final Report October 2014 Page 4 of 49 UK Roadmap-2014: Laser-based

Laser-based Manufacturing Applications:

UK Roadmap-2014

Final Report

October 2014

Laser-based Manufacturing Applications UK Roadmap-2014 Final Report October 2014

Page 2 of 49

Laser-based Manufacturing Applications

UK Roadmap-2014

FINAL REPORT

October 2014

CONTENTS

0.0 Executive Summary

1.0 Introduction

2.0 Development of UK Roadmap-2014

2.1 Methodology: Workshop Design and Information Gathering 2.2 Methodology: One-Day Roadmapping Workshop 2.3 Methodology: Electronic Data Compilation and Interim Report

3.0 Outputs from Roadmapping Workshop

3.1 Overview 3.2 Market Drivers and Needs 3.3 Prioritisation of Laser-based Manufacturing Application Areas

4.0 Deeper Exploration of Four Short-listed Application Areas

4.1 Generation of Specific Roadmaps for Short-listed Manufacturing Application Areas 4.2 Links of Shortlisted Application Areas to Market Drivers

5.0 Technologies and Required R&D Priorities

5.1 Research and Development Priorities 5.2 Strengths, Weaknesses, Knowledge Gaps and Enablers

6.0 Consultation with UK Community 6.1 Summary of Consultation Responses

7.0 Conclusions

8.0 References

Appendices A Workshop Attendee List

B Guidance Notes for pre-Workshop Homework

C Workshop Programme Agenda

D Attendee Groups for Detailed Exploration of Selected Application Areas

E Post-Workshop Community Consultation Questionnaire


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List of Figures and Tables Figure 1: Slide one of the Pre-Workshop Set of Three Homework Templates. ...................................... 9 Figure 2: Slide two of the Pre-Workshop Set of Three Homework Templates. .................................... 10 Figure 3: Slide three of the Pre-Workshop Set of Three Homework Templates. ................................. 10 Figure 4: Summary of the Overall Roadmap Prior To Prioritisation ...................................................... 13 Figure 5: Total votes received for all the Opportunity factors and all the Feasibility factors. .............. 17 Figure 6: The top four Opportunity factors and the Top three Feasibility factors selected and

used in the workshop............................................................................................................. 18 Figure 7: UK Roadmap Showing Prioritised Laser-Based Manufacturing Application Areas ................ 19 Figure 8: Indication of how the 2x2 matrix of Feasibility and Opportunity was used during the

Workshop. .............................................................................................................................. 20 Figure 9: Blank Work-Book Template Used to Generate Roadmap for Short-Listed Application

Areas. ..................................................................................................................................... 22 Figure 10: E-version of Completed Roadmap template for Additive Manufacturing including

Repair ..................................................................................................................................... 23 Figure 11: Consolidated Roadmap for Additive Manufacturing including Repair ................................ 24 Figure 12 E-version of Completed Roadmap template for Joining dissimilar materials. ...................... 25 Figure 13: Consolidated Roadmap for Joining dissimilar materials. ..................................................... 26 Figure 14: E-version of Completed Roadmap template for Surface processing and modifications ..... 27 Figure 15: Consolidated Roadmap for Surface processing and modifications...................................... 28 Figure 16: E-version of Completed Roadmap template for Micro-manufacturing. .............................. 29 Figure 17: Consolidated Roadmap for Micro-manufacturing. .............................................................. 30

Table 1: Prioritised list of Independently Selected Market and Industry Drivers ................................. 14 Table 2: Links of the market drivers & needs to the selected laser-based manufacturing

Application Areas. .................................................................................................................. 31 Table 3: Relevance of R&D priorities to Short listed Application Areas ................................................ 33 Table 4: Strengths Weaknesses, Knowledge Gaps and potential enablers for UK laser-based

Manufacturing ....................................................................................................................... 35


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UK Roadmap-2014: Laser-based Manufacturing Applications

Executive Summary

The primary objective of the Roadmapping exercise is to identify new and evolving manufacturing applications where laser processing may play a significant enabling role, e.g. for high-value-added components and systems and those fabricated from new/mixed engineering materials, or relating to new production techniques. In addition, the aim is to identify relevant areas where research and development would be required to facilitate future laser-based solutions to such production needs, for example in new laser-material process science and technology, new or enhanced laser source development, beam manipulation and delivery, and system integration/control issues. Such a roadmap must embrace the needs of both UK industry and researchers, including laser-users in manufacturing and those in the technology-supply chain. It could also contribute to the evidence-base for strategic planners and UK funding agencies.

A longer-term goal is to develop a broad-based national strategy to stimulate significant growth in the adoption of laser-based technologies in UK manufacturing industry. In this context, the Roadmapping activity, while of considerable value in its own right is also viewed as a relevant first step towards the more ambitious goal of engaging the UK community in developing a coherent focus on achieving increased recognition of the commercial benefits of these technologies to enable increased ‘industry pull’.

With these objectives in mind, a Roadmapping Workshop was proposed by the EPSRC Centre for Innovative Manufacturing in Laser-based Production Processes (CIM-LbPP) and the Association of Industrial Laser Users (AILU), and subsequently organised in partnership with the Institute for Manufacturing (IfM) at Cambridge University, using Roadmap-Workshop methodologies the Institute had previously developed. The IfM also provided the outline Workshop design and led the programme facilitation of the Roadmapping Workshop, which took place on 04 March 2014 in London at the Institute of Physics Headquarters, attracting participants from UK industry, academia and the public sector.

From a pre-Workshop independent information gathering stage and subsequent work on the day, the key market and industry drivers and needs were identified as the following:

New laser and machine processing capabilities to enable processing of dissimilar, advanced or brittle materials as well as integrating various processes into one laser system;

Cost reduction of laser-based manufacturing hardware, including maintenance and lifetime cost of ownership to respond to global financial pressures;

The need for automation and real time decision making to enable product customisation;

The development and deployment of improved/new lasers including high power and tuneable lasers, picosecond (ps), and femtosecond (fs) lasers.

Systems with reduced environmental impact via decreased energy consumption of laser tools, lighter and stronger structures for laser systems; reduced material utilisation and production waste.

Roadmapping Workshop Conclusions The priority laser-based manufacturing application areas identified were predominantly around manufacturing techniques that are applicable to a variety of products and markets as follows:

Additive Manufacturing including Repair;

Joining materials including both thin and thick, similar and dissimilar materials;

Surface processing and modification;

Micro-manufacturing.


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The most important underpinning technologies and R&D priorities required to deliver these application techniques were identified as:

Fundamental laser process science to improve the understanding of laser-material interactions and eliminate the “black art” associated with some current processes;

Development of better process output monitoring, analysis and control;

Development of improved and new lasers and laser systems as well as their integration into machines, tools and equipment;

Improvements of the laser beam delivery and control to enable better manufacturing precision and speed;

Development of better and more sophisticated, high speed scanners and scanning systems.

The UK was seen as strong in solid state and fibre laser technologies, with highly-rated academic laser research and expanding commercial laser companies. The UK is also highly capable in research areas underpinning the development of next generation lasers and laser systems such as optics, modelling and simulation, sensors, analysis and monitoring systems.

The low UK market take-up/demand for laser-based systems in manufacturing (e.g. compared to Germany), which is evident across diverse areas of UK industrial engineering appears to indicate a low level of appreciation of the commercial benefits of these technologies, and is identified as a key focus area for future strategic planning.

Community Consultation To enable inputs from the wider industrial laser community, a ‘Consultation Process’ was organised, for which the Interim Roadmap-2014 Report plus a focused Questionnaire was circulated by email to more than 120 colleagues in industry and academia. Despite the relatively short response time and the inconvenience of the summer timing of the Consultation, responses from more than 50 colleagues were received before the deadline.

In general, the consultation responses indicated broad (even strong) agreement with the outcomes from the Roadmapping Workshop as outlined in the Interim Roadmap Report. There were no serious disagreements expressed and few negative comments.

Moreover, the Consultation produced two important additional suggestions/conclusions, as follows:

The most frequently recognised ‘additional issue’ identified by the consultation, articulated in different ways in more than 25% of the responses relates to the need for action to stimulate a higher level of “pull” from manufacturing industry to enable increased exploitation of the undoubted benefits of laser-based production processes. The broad-based and strongly-expressed view was that an important socio-economic priority be added to the list of technical priorities. This should involve strategic research aimed at improved understanding the UK manufacturing scene with quantification of laser-process usage, recognition of barriers and the development of plans to facilitate the required industry “pull”.

The second significant point raised was the suggestion (accepted) that a well-structured Short Version of the Roadmap-2014 Report (4-pages) is necessary as the principal vehicle for addressing policy makers and other stake-holders.


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UK Roadmap-2014: Laser-based Manufacturing Applications

1.0 Introduction

A principal outcome of the Workshop on Laser Materials Processing (LMP) held at Farnham Castle in February 2012 [1] was a widely-shared recognition of the need to produce a UK Roadmap, relating both to laser-based manufacturing applications/markets and future requirements for technologies and hardware. It was agreed that such a document would need to have relevance for UK companies and researchers (including laser-users in manufacturing and those in the technology-supply chain), as well as contributing to the evidence-base for strategic planners and UK funding agencies.

To achieve this goal, the Association of Laser Users (AILU) partnered with the EPSRC Centre for Innovative Manufacturing in Laser-based Production Processes (CIM-LbPP) with the aim of coordinating inputs from both industrial and academic sectors of the UK laser-based manufacturing community. In planning the production of a UK Roadmap, the support and encouragement of the Department for Business, Innovation and Skills (BIS) and the Electronics, Sensors and Photonics Knowledge transfer Network (ESP KTN) are gratefully acknowledged. Moreover, there is recognition that we are not starting from scratch, since in addition to the Farnham Report [1] there are also Europe-wide Photonics21 Roadmaps [2], to which many in the UK community have contributed.

Objectives The most immediate objective of the Roadmapping exercise is to identify new and evolving manufacturing applications where laser processing may play a significant enabling role, e.g. for high-value-added components and those fabricated from new/mixed engineering materials, or relating to new production techniques. In addition, the aim is to identify relevant areas where research and development would be required to facilitate future laser-based solutions to such production needs, for example in new laser-material process science and technology, new or enhanced laser source development, beam manipulation and delivery and system integration/control issues.

There is significant anecdotal evidence and widespread belief in the UK community that the take-up and exploitation of laser-based manufacturing technologies in UK industry is at a lower level than is healthy for an manufacturing economy seeking to recover its balance with services, and is much less utilised in this country than by our international competitors. Moreover, UK-based companies operating in the global supply-chain for laser-based manufacturing machines, such as laser source and system manufacturers continue to suffer from a generally weak home market, driving them to export a very large fraction (frequently >95%) of their production. Moreover, it is relevant (and chastening) to note the low-level of recognition that exists across large swathes of UK industry of the technical benefits and commercial opportunities which laser/photonics-based technologies offer to manufacturers in diverse industry sectors.

This fact is spectacularly exemplified in a recently-published report (‘The Future of Manufacturing: An Era of Opportunity and Challenge for the UK’ [3]) by a Foresight Team working for the UK Government Office for Science describing technologies key to the future health of high value manufacturing in the UK. Far from highlighting the technical benefits and commercial opportunities of laser-based manufacturing processes, as emphasised (for example) in the Factories of the Future EU documentation [4], or in relevant US documents [5, 7], in the UK Government Report – the word ‘laser’ did not warrant a single mention in the 250+ page document!

These considerations have to a significant degree underpinned a longer-term objective of the AILU/CIM-LbPP joint initiative, namely to develop a broad-based national strategy to stimulate significant growth in the take-up and exploitation of laser-based technologies by UK manufacturing industry. In this context, the Roadmapping activity, while of considerable value in its own right is also viewed as a relevant first step towards the more ambitious goal of engaging the UK community


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in developing a strategic focus on achieving national growth in the industrial exploitation of laser-based manufacturing technologies.

So, whilst fully recognising the global scale of this business, an important objective for the UK industrial laser community is to alert a larger fraction of UK manufacturers (as well as UK government industrial policy makers) to the powerful enabling features of laser-based processes in manufacturing, and particularly at the high-added-value end of the market.

2.0 Development of UK Roadmap-2014

The generation of an effective Roadmap demands the integration of technical, strategic and market inputs from as broad a distribution as possible of active professionals drawn from the UK industrial laser-based manufacturing community, with representation from both the industrial and academic sectors.

In an effort to achieve as large and diverse a set of inputs from across the UK community as possible within a reasonably structured set of activities, a multi-step process was conceived as follows:

One-Day Roadmapping Workshop and Interim (Draft) Roadmap Report; Process of consultation with the UK Industrial Laser Community; Production and dissemination of the Final UK Roadmap-2014 Report.

The key element in the formulation of a draft UK Roadmap was the One-Day Roadmapping Workshop, for which a three-phase Methodology was employed as follows:

1) Pre-Workshop Workshop Design and Information Gathering,

2) The Workshop One-Day Roadmapping Workshop,

3) Post Workshop Data Compilation and Interim Report

2.1 Methodology: Workshop Design and Information Gathering

Aims and Desired Outputs The primary aim of the Roadmap exercise is to use the foresight and professional skills of the UK community to identify new and evolving manufacturing applications and growing markets, where laser-based manufacturing technologies may play a key role in achieving technical and commercial success. In seeking such information, the methodology that was adopted sought to generate outputs via a process of gathering independent inputs from industry professionals regarding their opinions on key future important manufacturing applications and markets, as well as the key factors which drive market growth and industry expansion in these industries. For any application or market, it is also crucial to identify the criteria which define the scale and probability-of-success of a given opportunity, as well as to recognise the criteria which delineate the technical and commercial feasibility that a given opportunity can realistically be exploited.

Workshop Attendees In planning this event, the team from AILU and CIM-LbPP received advice and guidance from the Institute for Manufacturing (IfM) at Cambridge University, who had previously organised many similar Roadmapping events and count branches of government and multiple companies among their impressive client list. The experience of IfM professionals with this type of Workshop strongly suggested a limit for on-site participation of about 30, and this roughly matched the facilities available at the available London location at the Institute of Physics Headquarters. Faced with this difficult selection task, the (AILU/CIM-LbPP) organising team sought to produce an attendee list with the following criteria:

A majority of industrial colleagues - with a target industry/academia ratio of 4:1, A balance between laser ‘users’ and those in the hardware supply chain, and A broad experience balance.


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Fortunately, a large fraction of invitees were able to attend, with only a few not available due to diary conflicts; the final list of Workshop Attendees is shown in Appendix A. Moreover, efforts were made to include non-attendees and attendees alike in a pre-Workshop ‘Homework Stage’, so that a significantly larger fraction of the UK LMP community could contribute even at this early stage. Thus in parallel with distribution to Workshop participants, the slide-set ‘homework’ templates were also emailed to more than 100 industry professionals from the AILU data base.

Workshop Architecture and Pre-Workshop Work Templates As indicated, a set of three homework slides, reproduced below, was emailed to all attendees (and

>100 non-attendees) with instructions to return the completed slide-templates in time for pre-Workshop compilation of the data, to gather independent participant inputs. Some brief Guidance Notes (reproduced as Appendix B) and including the Workshop Agenda were sent with the ‘homework’.

Slide 1 Requested participant opinion of the top two Market and Industry Drivers and the most important Manufacturing Applications of laser-based technology over the next three, seven and ten year periods (see Figure 1);

Slide 2 Requested participant opinion of the top five criteria from a prescribed list defining a market opportunity for a given manufacturing application (see Figure 2);

Slide 3 Requested participant opinion of the top five criteria from a prescribed list defining the feasibility of a given manufacturing application (see Figure 3).

The inputs (votes) from Slides 2 and 3 were collected (by email) and consolidated by the IfM team. Then the criteria that collected the most votes were set up to be used during the Workshop to prioritise from the full list of suggestions provided on Slide 1 for drivers and applications.

Having agreed its final ‘design’, the IfM team used the week prior of the Workshop to cluster all the received input data, and to prepare the collateral material required for use on the day including facilitation PowerPoint slides, large printed wall-posters and participant hand-outs.


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Figure 1: Slide one of the Pre-Workshop Set of Three Homework Templates.

Laser-based Manufacturing Applications – Roadmapping Workshop

Timeline Short(3 years)

Medium (7 Years)

Long (10 Years)

Market and Industry Drivers

1. …

2. …

1. …

2. …

1. …

2. …

Manufacturing Applications

1. …

2. …

1. …

2. …

1. …

2. …

Required system Hardware This section to be completed during the workshop

Supported byWorkshop initiated by

Name: Organisation:

Slide 1


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Figure 2: Slide two of the Pre-Workshop Set of Three Homework Templates.

Figure 3: Slide three of the Pre-Workshop Set of Three Homework Templates.

DIMENSION FACTOR DEFINITION

VOLUME

Market sizeSize of potential market, or number of potential

adoptions, reasonably available to us.

Our sales potential in a

given timeSales volume or number of adoptions anticipated

in a defined time (say, 5 years)

Synergy opportunitiesPossible additional benefits to other projects or

activities; or the possibility of new opportunities in

combination.

Customer benefitIdentifiable benefit to customers (internal or

external) or potential adopters

Competitive intensity in

MarketNumber or significance of the competition

MARGIN

Increased margin, or

benefit per unit

Improvement in product margin (eg by cost

reduction or price premium) compared to existing

products; or benefit to us per adoption

Business cost reduction or

simplificationFacilitates cost reduction or simplification of

business processes

Industry/market readinessHow easy will it be for customers or adopters to

take up the product; do they have to change their

behaviour or processes?

PLATFORM FOR FUTURE BENEFIT

Market growth Anticipated growth rate of market

Future potentialProduct is a platform for future products or could

open new markets in future

INTANGIBLES

Learning potentialWill improve the knowledge or competence of the

business

Impact on Brand Image Effect on Brand image or staff morale

Impact on key customer

relationsImportance for relations with key customers

Factors forOpportunity

Slide 2

DIMENSION FACTOR DEFINITION

CHARACTERISTICS OF THE APPLICATION/PROCESS OR PRODUCT

Application/Process or

Product differentiationHow well the application/process or product is

differentiated from those of major competitors

Sustainability of

competitive advantage

Our ability to sustain competitive position (eg

IPR, Brand strength etc), using the Application,

Process or product

Technical challengeHow confident are we that the proposed

Manufacturing application/Process or Product is

technically feasible?

Market knowledgeOur understanding of size and requirements of

the market that the Manufacturing process or

Product will enable

CAPABILITY Technical capabilityDo we have the required technical competence

to implement the manufacturing application/

process or design the product?

SUPPORTING BUSINESS PROCESSES

Fit to sales and/or

distribution capacityFit to our sales competences and/or distribution

chain

Fit to manufacturing

and/or supply chain Ability to exploit new manufacturing process or

supply the new product

Finance Availability of finance for the project

ORGANISATIONAL BACKING

Strategic fitHow well does the proposal new manufacturing

process or product fit our company strategy?

Organisational backing Level of staff or management backing at an

appropriate level

Factors forFeasibility

Slide 3


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2.2 Methodology: One-Day Roadmapping Workshop

The One-Day Workshop took place on 04 March 2014 at the Institute of Physics HQ in Portland Place, London. The event design and application of roadmap methodology to the specific case of the Laser-based Manufacturing Applications field was led by Dr Nicky Athanassopoulou from the IfM who, along with her colleague John McManus, facilitated the event on the day, ably assisted by Veronica Ferguson and Alex Peden from the CIM-LbPP team, and Karen Brakspear from EPSRC and Louise Jones from the Knowledge Transfer Network.

The day began with introductions of all present, a short background presentation from Professor Duncan Hand (CIM-LbPP Director), and an overview of the programme for the day from Dr Athanassopoulou and John McManus.

The main activities are summarised as follows (for full Programme, see Appendix C):

1. Homework – Slide 1: The Workshop commenced with 2-minute presentations from each participant, summarising individual, independent views of (a) the most important Market and Industry Drivers over the short-term (3 years) medium-term (7 years) and long-term (10 years), and (b) the most important future laser-based Manufacturing Applications.

2. Homework – Slides 2 and 3: A discussion of the remainder of outcomes of the Homework assignment aimed at producing an agreed set preferred criteria to be used to prioritise the overall list of Manufacturing Applications;

3. The agreed criteria were then used as each participant individually cast three votes (from the full collective list) to create a short-list of the most promising manufacturing applications to be subject to further exploration later in the day;

4. In the afternoon session, four groups were created to explore in more depth the short-list of manufacturing applications, and to identify the required technology developments, most important R&D priorities and any anticipated opportunities for collaboration;

5. Finally, the common research themes emerging from the shortlisted laser-based manufacturing applications were identified;

2.3 Methodology: Electronic Data Compilation and Interim Report

The final component of the Workshop was the compilation and transcription of all outputs from the activity of the one-day event into an electronic format including some data analysis of the content. This information was then compiled in a document [6] prepared by the Cambridge IfM Team, which has been used extensively in preparing the final sections of this Interim Report.


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3.0 Outputs from Roadmapping Workshop

3.1 Overview

A total of 36 people contributed to the Workshop including 26 from industry, 6 from universities, and 3 from government, of whom 29 attended the Workshop, plus 6 Facilitators as mentioned in Section 2.2.

As indicated, the Roadmap was designed to include two broad layers:

1. Market and Industry drivers, and 2. Laser-based manufacturing applications,

with projections over short- (2017), medium- (2021) and long-term (2024).

The market and industry drivers were further subdivided into the following strands:

Macroeconomic drivers such as social, technological, environmental, economic, geo-political and legal;

Industry needs for future laser-based manufacturing applications; Industry needs for new laser-material interaction processes; Industry needs for new lasers, photonic components and system technology.

Overall a total of 24 distinct market and industry drivers were identified, broadly distributed over the short, medium and long term. Most were either from the macro-economic environment or relating to future industry needs for laser-based manufacturing applications and new laser-material interaction processes. The data shows that the drivers and requirements identified for new laser-material interaction processes, new lasers, new photonic components or new system technologies, are aimed more at medium to long term.

In total 51 laser-based manufacturing applications were identified with over 80% of those in the short and medium term, with ~40% of the proposed applications were focussed on laser-based manufacturing techniques required for emerging engineering materials and material combinations.

The laser-based manufacturing applications were also subdivided into the following layers:

New laser-based manufacturing applications; Enhancements of current laser-based applications; Applications for which a specific (new) laser-based process is required to implement new

production technology Applications for which new engineering materials and material combinations require new

laser-based manufacturing techniques Other

A schematic Summary of the Roadmap prior to prioritisation is shown in Figure 4.


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Figure 4: Summary of the Overall Roadmap Prior To Prioritisation

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Page 14 of 49

3.2 Market Drivers and Needs

Opinions on the most important industry drivers and needs collected from contributors in advance of the workshop were clustered into common groups. Then depending of the number of contributions (frequency) per group, a prioritised list of the market drivers and needs was developed, as shown in Table 1.

The results showed that of these submissions, the top five-rated market and industry drivers and needs were:

A. New laser and machine processing capabilities to enable processing of dissimilar, advanced or brittle materials as well as integrating various processes into one laser system.

B. Reduction of laser manufacturing systems costs including maintenance, finance etc. (overall cost of ownership) over the laser systems lifetime to enable companies and organisations to respond better to global financial pressures.

C. The need for process automation (real time monitoring, adaptive control and process algorithms). This was considered as a key enabler to mass product customisation (e.g. fashion items, Ultrabook laptops) as well as highly individualised components and products.

D. The development and deployment of improved and / or new lasers including tuneable and high power lasers; picosecond (ps) and femtosecond (fs) lasers; lasers with enhanced properties (e.g. brightness, selectable pulse duration, locking, beam manipulation etc.); low-cost, high power diode lasers with dense wavelength division multiplexing (HPDL DWDM); Multipurpose lasers with high degree of flexibility but high precision.

E. The need to reduce environmental impact by reducing the energy consumption of laser tools, producing lighter and stronger structures and improving laser-based manufacturing processes to reduce material utilisation and production waste.

The ‘letter designations’ (A, B, C etc.) are also used as indicators in Figure 4.

Table 1: Prioritised list of Independently Selected Market and Industry Drivers

Group Detail of Driver or Need

Time-frame

Layer in the roadmap

Freq.

A

New Laser Processing / Processing Machine Capabilities

High precision prototypes by laser sintering; Welding dissimilar materials, metal to ceramic/glass; Combining processes, i.e. cut/weld and mark piece in one op rather than two machines; Stress-free optical bonding for beam and image transmission; Reduced distortion and heat affected zones; Athermal materials and reduce outgassing; Wider range of standard processing conditions, High-efficiency beamshapers for high-power CW and high fluence ns and ps pulse applications; Elimination of scrap by dynamic control of the laser based processes; Comparison of SS and CO2 lasers for HP welding.

Short to Long

New Material Processing

19

B

Reducing Manufacturing and Laser System Costs

Reduction in manufacturing costs; Automated manufacture; Speed of manufacture; Lower ownership-cost of laser-based machines; Cost reduction by fabrication of complex structures; Reduced cost; Product by better use of materials & processing costs; Reduced equipment costs; Reduced maintenance costs; Lower ownership-cost of laser-based machines; Low lifecycle cost of laser system technology; Reduce “photon cost”

Short to Medium

New Lasers and Components

19

C Automation and Intelligence to

Elimination of manual alignment; Fully automated intelligent processing; Increasing impact of real-time process control; Adaptive control and

Medium to Long

Future Laser-Manuf Apps

17


Page 15 of 49


Time-frame


Freq.

Enable Product Customisation

process algorithms; Remote access; Trend towards mass customisation of products e.g. fashion items, laptops; True mass customisation enabled by highly flexible laser-based manufacturing systems (pulse length, wavelength, material handling etc.); Highly individualised components/products

D

New / Improved Industrial Lasers - More power, lower cost

Tuneable power lasers; Laser with enhanced properties (e.g. brightness, pulse durations etc.); Reduced energy consumption (source & process) Low-cost HPDL DWDM, phase locking, beam manipulation; Easier deployment of ps and fs system à Conventional and beamshaping optics for high average power, high reliability ps and fs use; Fibre delivery of ps and fs pulses; Laser sources development; Multipurpose lasers with high degree of flexibility but high precision

Short to Long

Future Laser-Manuf Apps

12

E Environmental / Energy Costs & Consumption

Reduced environmental impact e.g. low chemical waste; As energy costs increase, low energy consumption of laser tools advantageous to conventional tools; Environmental – lighter and stronger structures; More electrically efficient laser sources and systems Resource efficiency = <material utilisation, <energy; Environmental issues influencing design parameters & manufacturing process efficiency

Short to Long

STEEPLE 10

F Enhanced / Integrated Laser-based Systems

Integrated electronics in other parts/devices; Integration of lasers in robotic machine tools; Microelectromechanical systems; Integrated solutions; Sensors & QA

Long Future Laser-Manuf Apps

6

G New AM capability

AM developments for small /medium size aero / auto components; AM for large and multi-material components; Larger volume and faster build rate additive layer; Stress management for AM processes; Low cost AM processes allowing for medium volume manufacture

Long Future Laser-Manuf Apps

6

H Improving Knowledge Transfer

Transition of knowledge to industry, confidence building; Quick response to industry needs (companies & technology); Wider engagement with manufacturing industries having UK-strength; Wider & deeper engagement with Photonics 21 policy making & projects; Lasers, systems & tech development for non-UK strength manufacturing applications worldwide

Short to Medium

Other 6

I

Ability to produce Multifunctional structures

Multifunctional structures; Large area micro-surface texturing (functional surfaces); Improved product performance; Greater functionality in product produced by LMP feature generation

Medium

Industry Needs for New laser-material interaction processes

5

J Flexible Manufacturing

Flexible tooling; Flexible manufacturing; Flexible and application-specific processing conditions à Application-specific beamshapers for high-power CW and high fluence ns and ps pulse applications

Short to Medium

Industry Needs for Future Laser-based Manufacturing Applications

5

K Mobile / Portable Laser Systems

Portable compact robust lightweight laser systems; Lightweighting; Cost-effective, local “at the place” manufacturing / customisation / modification; Localised manufacturing

Medium to Long


5

L Economic, Political & Regulatory

US Govt. regulations making identifier coding marking mandatory e.g. medical equipment; Re-industrialisation of Europe. EU goal to increase current industry GVA from 16% to 20% by 2020; Political drive & policies

Medium STEEPLE 5


Page 16 of 49


Time-frame


Freq.

Changes in Macroeconomic Environment

promoting UK Manufacturing; Economic sustainability of UK manufacturing

M

Ability to process Composites & Complex Materials

More complex materials and combinations (welding and cladding); Advanced materials; Composite material use in lightweight vehicles

Medium

Industry Needs for New laser-material interaction processes

4

N

Enabling higher manufacturing / processing speeds

Improved speed in laser based manufacturing; Increase speed/lower cost - Parallel processing, high speed scanning etc.; Higher throughput for short-pulse systems à High damage threshold components for ns and ps pulses

Short


4

O

Improving Product Reliability & Consistency

Consistency of manufacture; Environmental – reduced remanufacturing by increased component lifetime in service; Lower cost, more reliable lasers

Short


4

P Miniaturisation

Medical device miniaturisation – to the extent that ‘robotic’ nanoscale MEMs for insertion into bloodstream, etc.; Reduced feature size in semicon EUV pump sources; Miniaturization - smaller features, Higher accuracy, Minimal damage & dross plus shorter wavelength, ultra short pulses

Medium to Long


4

Q

Just in Time Manufacturing & Lead time Improvement

Just in time; Lead time; Unpredictable demand = supply chain agility = <time enquiry to delivery

Short


3

R Requirement for Better Fuel Efficiency

Aircraft fuel efficiency, driven by environmental AND commercial imperatives; Automotive fuel efficiency

Short STEEPLE 3

S Social Changes Ageing population; Social mobility Medium STEEPLE 3

T Skills and Labour Requirements

Asian up-skilling = greater competition @ system level; Shortage laser process Engineers/ awareness; Alternatives to low cost off-shoring due to rising cost of labour in China = automation?;

Medium STEEPLE 3

U Improved Yield Improved component yield, 100% yield / productivity systems Medium to Long

Other 2

V High precision manufacturing

High value, high precision medical components; Processing increasingly small components with tight tolerances.

Short


2

Control Medium Other 1

Big Data Short Other 1


Page 17 of 49

3.3 Prioritisation of Laser-based Manufacturing Application Areas

Prioritisation Criteria Each laser-based manufacturing application was assessed using two different and roughly separate considerations, namely Opportunity and Feasibility. Opportunity was defined as the magnitude of the opportunity that is plausibly available to an organisation; while Feasibility was defined as how well-prepared an organisation is to grasp the opportunity.

For both Opportunity and Feasibility criteria, a list of factors had been provided to all participants in advance of the workshop (Homework Slides 2 and 3 in Figure 2 and Figure 3), and each participant independently selected those he /she considered to be the most appropriate for assessing the manufacturing applications. All received votes were consolidated in advance of the workshop, and the total number of votes received for each factor is shown in Figure 5. The four top-ranked Opportunity factors and the three top-ranked Feasibility factors were identified used during the rest of the workshop. These are shown in Figure 6.

Figure 5: Total votes received for all the Opportunity factors and all the Feasibility factors.


Page 18 of 49

Figure 6: The top four Opportunity factors and the Top three Feasibility factors selected and used in the workshop.

Prioritisation Chart A modified criteria-assessment process that involved two steps took place during the actual Workshop.

In the first step of this revised process (Opportunity Factors), each participant was asked to review the consolidated list of 51 listed Manufacturing Applications and to use the four top-ranked Opportunity factors (see Figure 6) to select independently between 4-8 choices from the Manufacturing Applications list. Participants were discouraged from voting for the Applications they had contributed unless they were part of consolidated group or cluster.

In the second step, participants were asked to consider only applications that had already been selected using the Opportunity Factors, and for each of those selected to independently select from 4-8 Manufacturing Applications based on the three top-ranked Feasibility factors (see Figure 6).

By this process, a shorter list of 24 laser-based manufacturing applications was derived, to be considered further later during the Workshop. This shorter list contained a good balance between short and medium term applications but most fell into the new laser-based manufacturing techniques required for new engineering materials and material combinations layer of the roadmap. This short grouped list of selected applications of applications is shown in the chart in Figure 7.


Page 19 of 49

Figure 7: UK Roadmap Showing Prioritised Laser-Based Manufacturing Application Areas

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Page 20 of 49

This reduced list was subsequently transferred onto a 2x2 matrix with Opportunity shown on the vertical axis and Feasibility on the horizontal axis (see Figure 8 for an indication of the process). The objective here was to facilitate decision making and selection of the most appropriate applications to explore in much greater depth during the second main phase of the Workshop.

Figure 8: Indication of how the 2x2 matrix of Feasibility and Opportunity was used during the Workshop.

Applications placed on the top right quadrant (High Feasibility and High Opportunity) were of immediate interest, while Applications on the bottom right quadrant (High Feasibility and Medium / Low Opportunity) may represent suitable more long-term opportunities. Applications placed on the bottom left quadrant (Low Feasibility and Low Opportunity) were not automatically dismissed since it is possible they might be ’enablers’ for other applications or in support of longer term prospects.

Final ‘Manufacturing Application Area’ Short List Selection Six Workshop participants were nominated by the Workshop sponsors (AILU and CIM-LbPP) to make a selection of applications (or groups of applications that could be assessed together) they considered most appropriate to take forward for more detailed investigation by expert groups of the Workshop participants. Four applications were selected using a consensus process that took into consideration the following aspects to achieve a balanced selection:

relative scores of each application and their position onto the 2x2 chart the timeline of the application (short, medium or long term) applications positioned most of the sub-layers of the roadmap the specific expertise of the Workshop participants

Prioritisation of Manufacturing Applications

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capabilities and processes

Y: 1G:389A.

Title: RemanufacturingWhen: M

Y: 1G: 3

131A.Title: Highly tailored functional materials e.g. incorporating mechanical, optical electronic functionsWhen: LY: 4G: 9

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?. High intensity

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Y: 7G:5

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Q. Large area processing

Y: 3G:3


Page 21 of 49

The four Application Areas selected for further exploration were:

1. Additive Manufacturing (AM) including Repair This included netshape and post processing, faster redesign of many components especially for aerospace applications, laser sintering, manufacturing of multi-materials and high speed powder bed fusion AM using combined laser and e-beam build processes.

2. Joining materials including both thin and thick, similar and dissimilar materials This included welding as a joining process, welding of lightweight structures, ability to weld ultra-high strength steel (UHSS), bonding of dissimilar materials e.g. glass-to-glass, glass-to-composites and sintering of crystalline powders into ceramics, adhesive-free bonding to eliminate contamination and stress-free optical bonding for beam and image transmission.

3. Surface processing and modifications This included laser texturing thin flexible glass for example to enhance the out-coupling for OLED lighting applications, laser cleaning/ablation technology, and general surface processing and modification applications.

4. Micro-manufacturing This included micro welding for medical and other applications, cutting of micro tubular components, microfluidics, micro-processing, parts assembly and placement, annealing and marking.

4.0 Deeper Exploration of Four Short-listed Application Areas

The Workshop participants were divided into four numerically roughly equal Groups based on individual background experience and declared interests, with each Group agreeing to explore one of the four Application areas in more depth. The distribution of Workshop attendees in each group was as indicated in Appendix D.

It was recognised at the outset that each of the four selected laser technology application areas can potentially address a broad range of manufacturing markets, including medical, aerospace, automotive, white goods, yellow goods, construction, defence, energy (oil and gas, renewables, nuclear), micro/macro electronics in displays, touch screens, sensors, MEMS and transport.

4.1 Generation of Specific Roadmaps for Short-listed Manufacturing Application Areas

The methodology used was for each of the four Groups to explore their Application Area using the following four sequential steps:

Step 1 The scope and boundaries of each application area was considered as well its long-term goal and vision.

Step 2 The links of each Application Area to the market drivers and needs were assessed;

Step 3 The groups then considered the technical feasibility especially in terms of the required system hardware, any success factors, knowledge gaps and the performance milestones that need to be put in place to implement the final vision.

Step 4 Finally, the key Research & Development priorities were summarised.

To assist the collaboration in working through these steps, each Group worked through the template shown in Figure 9 as a guide to the process. To facilitate these collaborations, each Group was issued with a very large poster version of Figure 9 to enable all members of each Group to ‘see the action’ and contribute to the creation of the embryo Roadmap for that topic. The documented outcome of these four intense parallel sessions was a completed version of Figure 9 (on a large Poster) for each of the four Manufacturing Application Areas.


Page 22 of 49

Figure 9: Blank Work-Book Template Used to Generate Roadmap for Short-Listed Application Areas.

The completed posters for each of the four Manufacturing Application Areas were transcribed by the IfM team in the days following the Workshop, and the FOUR e-versions (one for each Application Area) are shown in Figure 10, Figure 12, Figure 14 and Figure 16.

Using the content of the E-versions of Completed Roadmap poster templates as inputs, the IfM team generated the four high-level Roadmaps specific to each of the short-listed Manufacturing Application Areas.

Each of these Roadmaps includes: a more detailed specification for the application, the long-term vision for the application with the desired future performance

characteristics, the milestones necessary to achieve the vision, specific system hardware requirements for each milestone and desired initial actions.

These are shown in Figure 11, Figure 13, Figure 15 and Figure 17.

Application: Participants:: SUMMARY

STEP 1:

Scope and

Future Vision

What’s

IN:

1. What is the

Application?

What’s

OUT:

STEP 2:

Link to Key

Industry

Drivers / Needs

STEP 3:

Roadmap for

the Application

a. Demonstrators chain / stepping

stones / Steps towards opportunity

What? To whom? When? How?

Where? Why?

State of

Art Short term Medium-term Long-term 2. What is the

first

Demonstrator?

Actions?

b.

Required

System

Hardware

Enhanced/New lasers 3. Key

Technologies

RequiredLaser Beam management

Workpiece management

Laser/material process

monitoring

System integration/ control

Other

c. Success Factors

/ Knowledge Gaps

STEP 4:

Key R&D

priorities

4. Key R&D

priorities

What can help progress? Enablers? Strengths?

What can hinder progress? Barriers? Weaknesses?

What?

Why?

How ?

2-3 ~7 10+

Quantify? $

Applicationfunctionality, performance and format

Sub-system performancerequirements


Page 23 of 49

Figure 10: E-version of Completed Roadmap template for Additive Manufacturing including Repair

Ap

plic

atio

n:

Ad

dit

ive

Man

ufa

ctu

rin

gP

arti

cip

ants

::C

GR

, JS

, AW

, MG

, LS

SU

MM

AR

Y

ST

EP

1:

Sco

pe

and

Fu

ture

Vis

ion

Wh

at’s

IN:

1. W

hat

is t

he

Ap

plic

atio

n?

Wh

at’s

OU

T:

ST

EP

2:

Lin

k to

Key

Ind

ust

ry D

rive

rs /

Nee

ds

ST

EP

3:

Ro

adm

ap fo

r th

e

Ap

plic

atio

n

a. D

emo

nst

rato

rs c

hai

n /

step

pin

g s

ton

es /

Ste

ps

tow

ard

s o

pp

ort

un

ity

Wh

at?

To

wh

om

? W

hen

? H

ow

? W

her

e?

Wh

y?

Sta

te o

f Art

Sho

rtte

rm

Med

ium

-ter

mLo

ng-t

erm

2. W

hat

is t

he

firs

t?

b. R

equ

ired

Sys

tem

Har

dw

are

Enh

ance

d/N

ew la

sers

3.K

ey T

ech

no

log

ies

Req

uir

edLa

ser B

eam

man

agem

ent

Wor

kpie

cem

anag

emen

t

Lase

r/m

ater

ial p

roce

ss m

onito

ring

Sys

tem

inte

grat

ion/

con

trol

Oth

er

c. S

ucc

ess

Fac

tors

/ K

no

wle

dg

e G

aps

ST

EP

4:

Key

R&

D p

rio

riti

es

4. K

ey R

&D

pri

ori

ties

W

hat

?

W

hy?

H

ow

?

Low

→M

edia

nV

olu

me

Hig

h a

dd

ed v

alu

e.

Bas

ic p

roce

sses

an

d c

on

tro

l. L

aser

so

urc

es;

pro

cess

co

ntr

ol,

app

licat

ion

of

lase

rs.

Dif

fere

nt

mat

eria

ls, m

ult

iple

mat

eria

ls.

Rep

air.

Ph

ysic

al s

cale

an

d

shap

e o

f p

art.

Sen

sin

g an

d c

on

tro

l of

pro

cess

→b

row

n

po

wd

er

Dio

de,

So

lid s

tate

. La

sers

Acc

ura

cy –

no

rmal

m

anu

fact

uri

ng

tole

ran

ces

Low

val

ue

ho

me/

con

sum

er 3

D p

rin

tin

g. F

un

ctio

nal

gra

din

g m

ater

ials

. E

-bea

m.

Cla

dd

ing.

Ind

ust

rial

ised

ap

plic

atio

ns

10

0s

to 1

00

0s

(lo

w)

per

an

nu

m£

Bill

ion

mac

hin

es

Smal

ler

pro

po

rtio

n

for

lase

r so

urc

e va

lue

Med

ical

, Aer

o,

Mili

tary

, A

uto

mo

tive

. P

roto

typ

e/R

ig

par

ts →

to

war

ds

full

par

ts.

Cu

sto

m

par

ts p

erso

nal

ised

C-A

uto

mat

ion

an

d in

telli

gen

ce f

or

cust

om

isab

le p

rod

uct

. E

-Co

st a

nd

co

nsu

mp

tio

n.

J-Fl

exib

le m

anu

fact

ure

. D

esig

n f

reed

om

.

Dis

tort

ion

fre

e.

Favo

ura

ble

mic

ro

stru

ctu

re.

Favo

ura

ble

re

sid

ual

str

esse

s.P

rod

uce

fu

lly

den

se p

art.

(PB

) P

ow

der

bed

.

(BP

) B

low

n

po

wd

er.

Rep

air;

-B

P, -

Wir

eN

ear

net

sh

ape

→ n

et s

hap

e (b

oth

)

Pro

cess

co

ntr

ol

(bo

th).

Man

agin

g re

sid

ual

str

ess

(BP

)

Fully

den

se p

art

wit

h

corr

ect

mic

rost

ruct

ure

(b

oth

).

No

po

st p

roce

ss →

fi

nis

hed

pro

d (

bo

th)

2-3

~71

0+

Fully

den

se p

arts

. B

P

dis

tort

ion

fre

e b

ar

dem

on

stra

tor.

Mu

lti a

xis

com

ple

x sh

are.

Sh

ot

pee

nin

gw

ith

ou

t sh

ock

wav

e fl

uid

etc

. Li

nk

to A

M n

atio

nal

str

ateg

y &

p

ho

ton

ics

21

+H

20

20.

M

axim

um

sp

ot

size

m

ain

tain

ing

ou

tpu

t ch

arac

teri

stic

s. P

B s

urf

ace

fin

ish

fo

r fa

tigu

e p

arts

.

Scan

nin

g. S

op

his

tica

ted

. A

dap

tive

op

tics

. B

eam

d

eliv

ery

+ co

ntr

ol →

p

reci

sio

n +

sp

eed

.

30

0-5

00

w

lase

r (f

ibre

)

Lim

it s

ize

50

0

x 5

00

x 5

00

m

ax

wo

rkp

iece

.

No

pro

cess

co

ntr

ol

Lase

r p

een

ing

–n

ew s

ou

rces

Au

tom

atic

lo

ad/u

nlo

ad

Pro

gram

min

g an

d

sim

ula

tio

n t

o a

llow

ad

apti

ve o

pti

cs

Ad

apti

ve o

pti

cs –

mo

dif

yin

g b

eam

p

rofi

les

Mu

ltip

le b

eam

s?

Mu

ltip

le l

aser

s? –

Co

ntr

ol/

calib

rati

on

In s

itu

rep

air.

C

lose

d lo

op

p

roce

ss.

Lase

r p

ow

er n

ot

an

issu

e. B

eam

del

iver

y is

.

BP

so

ftw

are

and

loca

l man

ufa

ctu

re la

ckin

g. L

aser

lit

erac

y; -

engi

nee

rs, ‘

des

ign

ers.

Pro

cess

ca

pab

ility

. U

nd

erst

and

ing

pro

cess

cap

abili

ty –

engi

nee

rs.

Po

wd

er s

up

ply

ch

ain

–ri

sk.

Stre

ngt

h –

lase

rs (

solid

sta

te).

Res

earc

h (

Un

is);

-se

nso

rs, -

op

tics

, -m

od

ellin

g +

sim

ula

tio

n.

Dis

tort

ion

co

ntr

ol.

Un

der

stan

din

g h

eat

pro

file

s. T

itan

ium

inco

grad

ed m

ater

ial.

Mic

rost

ruct

ure

+ r

esid

ual

str

ess.

Las

er m

ater

ial i

nte

ract

ion

u

nd

erst

and

ing

→ p

ow

der

. P

roce

ss o

utp

ut

mo

nit

ori

ng

and

an

alys

is.

Can

pro

cess

co

ntr

ol f

or

lase

r p

roce

ss t

o o

ther

pro

cess

es?

Sys

tem

in

tegr

ato

rs.

Enco

ura

ge U

K s

up

ply

ch

ain

(A

M).

Mis

sin

g m

ach

ine/

too

l in

tegr

ato

rs.


Page 24 of 49

Figure 11: Consolidated Roadmap for Additive Manufacturing including Repair

Ad

dit

ive

Man

ufa

ctu

rin

g

Incl

ud

ing

:H

igh

adde

d va

lue.

B

asic

pro

cess

es a

nd c

ontr

ol.

Lase

r so

urce

s; p

roce

ss c

ontr

ol, a

pplic

atio

n of

lase

rs.

Diff

eren

t mat

eria

ls,

mul

tiple

mat

eria

ls.

Rep

air.

Phy

sica

l sca

le a

nd s

hape

of p

art.

Sen

sing

and

con

trol

of p

roce

ss →

brow

n po

wde

r

Exc

lud

ing

: Low

val

ue h

ome/

cons

umer

3D

prin

ting.

Fun

ctio

nal g

radi

ng m

ater

ials

. E

-bea

m.

Cla

ddin

g.

VIS

ION

Indu

stria

lised

app

licat

ions

100s

to 1

000s

(low

) pe

r an

num

.

Med

ical

, Aer

o, M

ilita

ry,

Aut

omot

ive.

Pro

toty

pe/R

ig p

arts

→ to

war

ds fu

ll pa

rts.

Cus

tom

part

s pe

rson

alis

ed

£Bill

ion

mac

hine

s

Sm

alle

r pr

opor

tion

for

lase

r

sour

ce v

alue

Dio

de, S

olid

sta

te.

Lase

rs

Acc

urac

y –

norm

al

man

ufac

turin

g to

lera

nces

MIL

ES

TO

NE

1

Nea

r ne

t sha

pe

→ n

et s

hape

(bot

h)

MIL

ES

TO

NE

2

Pro

cess

con

trol

(bot

h).

Man

agin

g

resi

dual

str

ess

(BP

)

SY

ST

EM

HA

RD

WA

RE

300-

500

w la

ser

(fib

re)

Lim

it si

ze 5

00 x

500

x

500

max

wor

kpie

ce.

No

proc

ess

cont

rol

MIL

ES

TO

NE

3

Ful

ly d

ense

par

t

with

cor

rect

mic

rost

ruct

ure

(bot

h).

FIR

ST

AC

TIO

NS

Ful

ly d

ense

par

ts.

BP

dis

tort

ion

free

bar

dem

onst

rato

r.

Mul

ti ax

is c

ompl

ex

shar

e. S

hot

peen

ing

with

out

shoc

kwav

e flu

id

etc.

Link

to A

M n

atio

nal

stra

tegy

&

Pho

toni

cs21

,

+H

2020

.

Max

imum

spo

t siz

e

mai

ntai

ning

out

put

char

acte

ristic

s.

PB

sur

face

fini

sh

for

fatig

ue p

arts

.

Sta

te o

f A

rt(2

01

4)

Sh

ort

ter

m (

20

17

)

Med

ium

-ter

m (

20

21

)

Lo

ng

-ter

m (

20

24

)

Vis

ion

SY

ST

EM

HA

RD

WA

RE

Lase

r pee

ning

–ne

w

sour

ces

Aut

omat

ic

load

/unl

oad

Pro

gram

min

g an

d

sim

ulat

ion

to a

llow

adap

tive

optic

s

SY

ST

EM

HA

RD

WA

RE

Ada

ptiv

e op

tics

–

mod

ifyin

g be

am

prof

iles

Mul

tiple

bea

ms?

Mul

tiple

lase

rs?

–

Con

trol

/cal

ibra

tion

SY

ST

EM

HA

RD

WA

RE

In s

itu r

epai

r.

Clo

sed

loop

pro

cess

.

MIL

ES

TO

NE

4

No

post

pro

cess

→ fi

nish

ed p

rod

(bot

h)


Page 25 of 49

Figure 12 E-version of Completed Roadmap template for Joining dissimilar materials.

Ap

plic

atio

n:

Jo

inin

gth

in d

issi

mila

r m

ater

ials

Par

tici

pan

ts::

Ro

ber

t L

amb

, Nei

l Mai

r, P

aul H

ilto

n,S

tew

art

Will

iam

s,

Nic

k L

ang

fiel

d, S

imo

n F

un

g (

?)

SU

MM

AR

Y

ST

EP

1:

Sco

pe

and

Fu

ture

Vis

ion

Wh

at’s

IN:

1. W

hat

is t

he

Ap

plic

atio

n?

Wh

at’s

OU

T:

ST

EP

2:

Lin

k to

Key

Ind

ust

ry D

rive

rs /

Nee

ds

ST

EP

3:

Ro

adm

ap fo

r th

e

Ap

plic

atio

n

a. D

emo

nst

rato

rs c

hai

n /

step

pin

g s

ton

es /

Ste

ps

tow

ard

s o

pp

ort

un

ity

Wh

at?

To

wh

om

? W

hen

? H

ow

? W

her

e?

Wh

y?

Sta

te o

f Art

Sho

rtte

rm

Med

ium

-ter

mLo

ng-t

erm

2. W

hat

is t

he

firs

t

Dem

on

stra

tor?

Act

ion

s?

b. R

equ

ired

Sys

tem

Har

dw

are

Enh

ance

d/N

ew la

sers

3.K

ey T

ech

no

log

ies

Req

uir

edLa

ser B

eam

man

agem

ent

Wor

kpie

cem

anag

emen

t

Lase

r/m

ater

ial p

roce

ss m

onito

ring

Sys

tem

inte

grat

ion/

con

trol

Oth

er

c. S

ucc

ess

Fac

tors

/ K

no

wle

dg

e G

aps

ST

EP

4:

Key

R&

D p

rio

riti

es

4. K

ey R

&D

pri

ori

ties

W

hat

?

W

hy?

H

ow

?

Low

→M

edia

nV

olu

me

An

y th

ickn

ess

incl

ud

ing

sim

ilar

and

dis

sim

ilar

lase

r h

ybri

d

syst

ems.

En

gin

eeri

ng

app

licat

ion

; m

edic

al, w

hit

e go

od

s,

yello

w g

oo

ds,

co

nst

ruct

ion

, def

ence

, en

ergy

(o

il +

gas

ren

ewab

les,

nu

clea

r), t

ran

spo

rt.

Ad

dit

ive

man

ufa

ctu

rin

g

D is

th

e d

rive

r fo

r (1

). B

&D

dri

vers

fo

r (2

). J

dri

ver

for

(2).

N d

rive

r fo

r (2

). B

&D

are

th

e sa

me.

E is

th

e d

rive

r fo

r (3

). C

is d

rive

r fo

r (3

). A

is o

ne

of

dri

vers

fo

r (3

). E

limin

atin

g T

dri

ver

for

(3).

H d

rive

r fo

r (3

). R

dri

ver

for

(4).

E d

rive

r fo

r (4

). M

dri

ver

for

(4).

Au

tom

oti

veW

hit

e go

od

sD

efen

ceTr

ansp

ort

EAR

LY

Exp

ert

op

erat

ed,

exp

ensi

ve a

nd

b

esp

oke

–ex

per

t. E

xper

t sy

stem

(4

).

Mat

eria

l sci

ence

(1

). E

lem

ent

of

wel

din

g (4

).

Dis

sim

ilar

mat

eria

ls (

3)

Bo

nd

a p

iece

of

glas

s to

met

al a

nd

ch

eck

for

corr

osi

on

etc

. O

pti

cal

qu

alit

y (1

). E

xper

t –

self

p

rogr

amm

ing

smar

t la

ser

(4),

(1)

, (3

). H

igh

po

wer

at

dif

fere

nt

wav

elen

gth

s im

pac

t o

n q

ual

ity

–ta

ilor

wav

e le

ngt

hs

(2).

De

-m

ysti

fyin

g th

e la

ser

wel

din

g p

roce

ss.

Imp

rove

th

e p

roce

sses

to

del

iver

hig

her

an

d c

on

sist

ent

qu

alit

y eg

hyb

rid

lase

rs (

1).

Pro

cess

mo

nit

ori

ng

exp

ert

syst

em (

4),

(1

), (

3).

On

line

insp

ecti

on

of

inte

rnal

def

ects

. C

hea

per

lase

rs o

ver

tim

e as

co

min

g d

ow

n (

2).

Exp

ensi

ve –

do

n’t

mak

e en

ou

gh –

too

mu

ch R

&D

! (2

). D

ynam

ic c

on

tro

l of

lase

r w

eld

ing

pro

cess

(4

),

(1),

(3

). F

ully

au

tom

ated

(4

) –

gau

ge t

he

exte

nt

of

req

uir

emen

t au

tom

atic

ally

. Se

lf

asse

ssm

ent

on

fa

ult

s/is

sues

(3

)

Dev

elo

pin

g ex

per

t sy

stem

s to

co

ntr

ol a

p

roce

ss a

nd

imp

rove

q

ual

ity

of

lase

r jo

inin

g.

Pro

cess

mo

nit

ori

ng

syst

ems

–fa

stre

spo

nse

sys

tem

s w

ith

dat

a p

roce

ssin

g. L

ow

co

st

lase

rs!

Full

pro

cess

co

ntr

ol.

El

imin

atio

n o

f th

e B

lack

Art

.

Use

of

tailo

red

en

ergy

d

istr

ibu

tio

ns

for

dis

sim

ilar

join

ing.

Dep

th

of

focu

s co

ntr

ol.

B

eam

wai

st.

Co

ntr

ol o

f fo

cus

po

siti

on

. M

icro

p

reci

sio

nin

gp

osi

tio

nin

g.

Pen

etra

tio

n c

on

tro

l.

Key

ho

le s

tab

ility

.

Go

od

mo

del

s th

at c

an w

ork

o

n P

C

esp

ecia

lly

dis

tort

ion

.

Bet

ter

assu

mp

tio

ns

and

mo

re

effi

cien

t m

od

els.

Lase

r co

st –

key

enh

ance

men

t o

wn

ersh

ip a

nd

man

ufa

ctu

rin

g co

st.

Po

rosi

ty c

on

tro

l. S

pat

ter

and

u

nd

ercu

t d

etec

tio

n a

nd

ove

r p

enet

rati

on

=>

inte

grat

ion

in

to

con

tro

l lo

op

. W

ell-

qu

alit

y co

ntr

ol.

W

eld

sh

ield

ing

(un

der

stan

d a

nd

co

ntr

ol)

. P

roce

ss c

on

tro

l gas

fl

exib

le c

lam

pin

g sy

stem

s.

Dis

tort

ion

co

ntr

ol a

nd

pre

dic

tio

ns.

To

olin

g an

d t

he

righ

t/st

and

ard

way

o

f d

oin

g. D

iod

e la

ser

800.

Sh

ort

er

wav

elen

gth

to

avo

id p

lasm

a p

lum

e,

bet

ter

abso

rpti

on

.

Mu

lti k

ilow

att

wav

elen

gth

–d

iffe

ren

t av

aila

ble

to

mee

t n

eed

s. D

iffe

ren

t m

ater

ials

.

Get

rid

of

bla

ck a

rt –

mo

re f

un

dam

enta

l sci

ence

!!!

In

colla

bo

rati

on

wit

h e

ngi

nee

rs.

Ap

pro

ach

th

e p

rob

lem

in

a

new

way

–n

ot

po

int

and

sh

oo

t. E

ngi

nee

rin

g st

and

ard

s to

co

ntr

ol t

he

pro

cess

(la

ck o

f)G

oo

d b

eam

an

alys

is s

yste

ms

> re

liab

le o

pti

cs,

bet

ter

lase

rs >

sta

ble

lase

rs.

Mak

ing

pro

gres

s o

n m

on

ito

rin

g sy

stem

s.

Pro

cess

mo

nit

ori

ng

and

co

ntr

ol.

1.

Exp

ert

syst

em d

evel

op

2.

Dis

tort

ion

/pro

cess

mo

del

ling

3.

Fun

dam

enta

l sci

ence

of

join

ing

4.

Gas

sh

ield

ing

un

der

stan

d

5.

Gas

es6

.P

oro

sity

co

ntr

ol

7.

Mat

eria

l sci

ence

of

dis

sim

ilar

mat

eria

ls

Imp

rove

d c

on

sum

able

s fo

r la

ser

wel

din

g. I

nte

rpre

tati

on

of

con

s w

ith

wel

d p

oo

ls.

1.

Go

od

qu

alit

y. A

s go

od

as

art

wel

din

g2

.C

ost

no

mo

re t

han

2 t

imes

th

at

of

art

wel

din

g3

.Ex

per

t sy

stem

s fo

r la

ser

con

tro

l4

.Jo

ins

for

fun

ctio

nal

ity

oth

er t

han

st

ren

gth

e.g

. Lig

ht

wei

ghti

ng


Page 26 of 49

Figure 13: Consolidated Roadmap for Joining dissimilar materials.

Join

ing

of

mat

eria

ls

Incl

ud

ing

:A

ny th

ickn

ess

incl

udin

g si

mila

r an

d di

ssim

ilar

lase

r hy

brid

sys

tem

s. E

ngin

eerin

g ap

plic

atio

ns in

med

ical

, whi

te g

oods

, yel

low

goo

ds, c

onst

ruct

ion,

def

ence

, ene

rgy

(oil

+ g

as r

enew

able

s, n

ucle

ar),

and

tran

spor

t. E

arly

ado

ptio

ns in

Aut

omot

ive,

Whi

te g

oods

, Def

ence

and

Tra

nspo

rt

Exc

lud

ing

: Add

itive

man

ufac

turin

g

VIS

ION

Join

ing

as a

rep

lace

men

t for

conv

entio

nal w

eldi

ng th

at

inco

rpor

ates

:

1.

Go

od

qu

alit

y. A

s go

od

as

art

wel

din

g2

.C

ost

no

mo

re t

han

2

tim

es t

hat

of

art

wel

din

g3

.Ex

per

t sy

stem

s fo

r la

ser

con

tro

l4

.Jo

ins

for

fun

ctio

nal

ity

oth

er t

han

str

engt

h e

.g.

Ligh

t w

eigh

tin

g

MIL

ES

TO

NE

2O

ptic

al q

ualit

y (1

).

Exp

ert –

self

prog

ram

min

g sm

art

lase

r (4

), (

1),

(3).

Hig

h po

wer

at

diffe

rent

wav

elen

gths

impa

ct o

n qu

ality

–

tailo

r w

ave

leng

ths

(2).

De-

mys

tifyi

ng

the

lase

r w

eldi

ng

proc

ess.

Im

prov

e

the

proc

esse

s to

deliv

er h

ighe

r an

d

cons

iste

nt q

ualit

y eg

hybr

id la

sers

(1)

.

Sta

te o

f A

rt(2

01

4)

Sh

ort

ter

m (

20

17

)

Med

ium

-ter

m (

20

21

)

Lo

ng

-ter

m (

20

24

)

Vis

ion

SY

ST

EM

HA

RD

WA

RE

Use

of t

ailo

red

ener

gy

dist

ribut

ions

for

diss

imila

r

join

ing.

Dep

th o

f foc

us

cont

rol.

Bea

mw

aist

. C

ontr

ol o

f foc

us

posi

tion.

Mic

ro p

reci

sion

ing

posi

tioni

ng.

Pen

etra

tion

cont

rol.

Key

hole

sta

bilit

y.

FIR

ST

AC

TIO

NS

Dev

elo

pin

g ex

per

t sy

stem

s to

co

ntr

ol a

p

roce

ss a

nd

im

pro

ve q

ual

ity

of

lase

r jo

inin

g.

MIL

ES

TO

NE

1

Exp

ert o

pera

ted,

expe

nsiv

e an

d

besp

oke

–ex

pert

syst

em(4

).

Mat

eria

l sci

ence

(1

).

Ele

men

t of w

eldi

ng

(4).

Dis

sim

ilar

mat

eria

ls (

3)

MIL

ES

TO

NE

3

Pro

cess

mon

itorin

g

expe

rt s

yste

m (

4),

(1),

(3)

. O

nlin

e

insp

ectio

n of

inte

rnal

def

ects

.

Che

aper

lase

rs

over

tim

e as

com

ing

dow

n (2

).

MIL

ES

TO

NE

4

Exp

ensi

ve –

don’

t

mak

e en

ough

–to

o

muc

h R

&D

! (2)

.

Dyn

amic

con

trol

of

lase

r w

eldi

ng

proc

ess

(4)

, (1)

,

(3).

Ful

ly

auto

mat

ed (

4) –

gaug

e th

e ex

tent

of

requ

irem

ent

auto

mat

ical

ly.

Sel

f

asse

ssm

ent o

n

faul

ts/is

sues

(3)

SY

ST

EM

HA

RD

WA

RE

Lase

r cos

t –ke

y

enha

ncem

ent o

wne

rshi

p an

d

man

ufac

turin

g co

st.

Por

osity

cont

rol.

Spa

tter

and

unde

rcut

dete

ctio

n an

d ov

er

pene

trat

ion

=>

inte

grat

ion

into

cont

rol l

oop.

Wel

l-qua

lity

cont

rol.

Wel

d sh

ield

ing

(und

erst

and

and

cont

rol).

Pro

cess

con

trol

gas

flex

ible

clam

ping

sys

tem

s.

Dis

tort

ion

cont

rol a

nd p

redi

ctio

ns.

Too

ling

and

the

right

/sta

ndar

d

way

of d

oing

. D

iode

lase

r

800.

Sho

rter

wav

elen

gth

to

avoi

d pl

asm

a pl

ume,

bet

ter

abso

rptio

n.

SY

ST

EM

HA

RD

WA

RE

Goo

d m

odel

s th

at c

an w

ork

on P

C e

spec

ially

dis

tort

ion.

Bet

ter

assu

mpt

ions

and

mor

e

effic

ient

mod

els.

SY

ST

EM

HA

RD

WA

RE

Mu

lti k

ilow

att

wav

elen

gth

–

dif

fere

nt

avai

lab

le t

o

mee

t n

eed

s.

Dif

fere

nt

mat

eria

ls


Page 27 of 49

Figure 14: E-version of Completed Roadmap template for Surface processing and modifications

Ap

plic

atio

n:

Su

rfac

e p

roce

ssin

g a

nd

mo

ds

Par

tici

pan

ts::

Ric

Allo

t, M

ark

Go

dss

ens,

Ad

am B

run

ton

, Mik

e G

reen

, Du

nca

n

Han

d, R

oy

McB

rid

e, K

aren

Bra

ksp

ear.

SU

MM

AR

Y

ST

EP

1:

Sco

pe

and

Fu

ture

Vis

ion

Wh

at’s

IN:

1. W

hat

is t

he

Ap

plic

atio

n?

Wh

at’s

OU

T:

ST

EP

2:

Lin

k to

Key

Ind

ust

ry D

rive

rs /

Nee

ds

ST

EP

3:

Ro

adm

ap fo

r th

e

Ap

plic

atio

n

a. D

emo

nst

rato

rs c

hai

n /

step

pin

g s

ton

es /

Ste

ps

tow

ard

s o

pp

ort

un

ity

Wh

at?

To

wh

om

? W

hen

? H

ow

? W

her

e?

Wh

y?

Sta

te o

f Art

Sho

rtte

rm 1

-2 y

ears

Med

ium

-ter

m 5

yea

rsLo

ng-t

erm

10

year

s2.

Wh

at is

th

e fi

rst

Dem

on

stra

tor?

Act

ion

s?

b. R

equ

ired

Sys

tem

Har

dw

are

Enh

ance

d/N

ew la

sers

3.K

ey T

ech

no

log

ies

Req

uir

edLa

ser B

eam

man

agem

ent

Wor

kpie

cem

anag

emen

t

Lase

r/m

ater

ial p

roce

ss m

onito

ring

Sys

tem

inte

grat

ion/

con

trol

Oth

er

c. S

ucc

ess

Fac

tors

/ K

no

wle

dg

e G

aps

ST

EP

4:

Key

R&

D p

rio

riti

es

4. K

ey R

&D

pri

ori

ties

Qu

anti

fy?

$

Ap

plic

atio

nfu

nct

ion

alit

y, p

erfo

rman

ce a

nd

fo

rmat

Sub

-sys

tem

per

form

ance

req

uir

emen

ts

Wh

at c

an h

elp

pro

gres

s?

Enab

lers

? S

tren

gth

s?

Wh

at c

an h

ind

er p

rogr

ess?

Bar

rier

s? W

eakn

esse

s?

W

hat

?

W

hy?

H

ow

?

Low

→M

edia

nV

olu

me

Ove

rlap

wit

h M

icro

mac

hin

ing

Lase

r m

arki

ng.

Len

ticu

lar

arra

ys. A

esth

etic

s. 1

0m

m d

epth

lim

it.

1 s

ec/d

iago

nal

inch

. $

20

Bn

. 10

0m

m r

es.

Cel

l/ti

ssu

e –

mat

eria

l in

tera

ctio

n in

med

ical

d

evic

es.

↓ a

ir/w

ater

res

ista

nce

Hyd

rop

hili

c/H

ydro

ph

ob

ic –

mic

rofl

uid

ics

Mec

han

ical

st

ren

gth

enin

g.Li

ghti

ng/

dis

pla

ys

Co

st/M

2(↓

sys

tem

co

sts)

, ↓ m

anu

fact

uri

ng

cost

s.

New

lase

r p

roce

ssin

g ca

pab

iliti

es

Imp

rove

en

viro

nm

enta

l im

pac

t/en

ergy

usa

ge. (

↓ch

emic

al u

sage

)

Co

mp

on

ent

lifet

ime

enh

ance

men

t.

Imp

rove

pro

du

ct r

elia

bili

ty

•Hig

h p

rf1

kw f

sla

ser.

•Hig

h s

pee

d

galv

osc

ann

ers.

•Hig

h s

pee

d

po

lygo

nal

.•C

hem

ical

/ m

ech

anic

al

pro

cess

es la

ser

po

lish

ing

•CM

2co

mp

atib

ility

•Id

enti

fy

con

tact

s/st

akeh

old

ers

/key

op

inio

n le

ader

•Dev

elo

p p

roce

ss

wit

h c

urr

ent

lase

r So

A.

Co

mp

are

to

oth

er c

om

pet

ing

tech

niq

ues

.

•M2

cap

abili

ty b

ut

↑

cost

.•R

edu

ce c

ost

s o

f (l

aser

) p

roce

ss.

•Dev

elo

p t

o “

real

” 3

D/2

D s

yste

ms

•M2

cap

abili

ty b

ut

↓

cost

hig

h t

hro

ugh

pu

t.•H

igh

ly r

elia

ble

sy

stem

•Lar

ge a

rea

mo

dif

icat

ion

, eg

10

cm

2 .•W

her

e su

rfac

e fu

nct

ion

alit

y is

ad

ded

.

•In

tegr

atio

n/s

ynch

ron

isat

ion

•Bea

m c

on

tro

l•R

eal-

tim

e (1

0x

fast

er)

sen

sor

con

tro

l•R

ob

ust

/ch

eap

er/2

4/

7 c

apab

le/u

ltra

fast

la

sers

.

•Hig

h P

RF

fsla

ser.

•Hig

h s

pee

d

galv

o&

po

lygo

n

scan

ner

Op

tim

ised

sh

ort

pu

lse

lase

rs (

po

wer

/rel

iab

ility

). H

igh

po

wer

UV

lase

rs.

•Im

pro

ved

bea

m

shap

ing/

cap

abili

ty.

•Dyn

amic

par

alle

l pro

cess

ing

•Hig

h s

pee

d•S

ynch

ron

isat

ion

of

scan

ner

s/st

ages

fo

r 2

D.

•Su

rfac

e p

rofi

le im

agin

g (i

nte

grat

ing

curr

ent

tech

no

logy

•3D

mu

ltia

xial

•Mat

eria

ls p

roce

ssin

g•R

eal t

ime

sen

sin

gH

igh

sp

eed

syn

chro

nis

atio

n o

f sc

ann

ers

& s

tage

s fo

r co

mp

lex

3D

•Sen

sors

fo

r 3

D w

ork

pie

ce•R

eal t

ime

feed

bac

k co

ntr

ol

Lack

of

focu

s –

beh

ind

co

mp

etit

ors

Go

od

un

der

lyin

g R

&D

cap

abili

ties

.

Mar

ket

is t

her

e (a

s is

su

pp

ly c

hai

n).

Bet

ter

ult

ra f

ast

lase

rs (

or

wh

at k

ind

of

lase

rs a

re n

eed

ed?)

–R

elia

bili

ty.

Pro

cess

ing

of

mu

ltip

le m

ater

ials

.

Pro

cess

dev

elo

pm

ent.

Mo

nit

ori

ng

and

co

ntr

ol s

yste

ms.

Syn

chro

nis

atio

n/p

aral

lel

pro

cess

ing.

Pee

nin

g. M

ake

surf

ace

stro

nge

r/sm

oo

ther

/Bio

insp

ired

/ ro

ugh

er.

Ad

ded

fu

nct

ion

alit

y -

↑↓

res

ista

nce

. Fr

icti

on

. C

on

tro

lled

sca

tter

ing

(ref

lect

ive

surf

aces

). H

eat

trea

tmen

t (a

lrea

dy

wel

l dev

elo

ped

). A

nn

ealin

g; -

Am

orp

ho

us

silic

on

, -So

lar.


Page 28 of 49

Figure 15: Consolidated Roadmap for Surface processing and modifications

Su

rfac

e P

roce

ssin

g a

nd

mo

dif

icat

ion

Incl

ud

ing

:P

eeni

ng.

Mak

e su

rfac

e st

rong

er/s

moo

ther

/Bio

insp

ired/

rou

gher

. A

dded

func

tiona

lity

-↑

↓

resi

stan

ce.

Fric

tion.

Con

trol

led

scat

terin

g (r

efle

ctiv

e su

rfac

es).

Hea

t tre

atm

ent (

alre

ady

wel

l dev

elop

ed).

Ann

ealin

g; -

Am

orph

ous

silic

on,

-Sol

ar.

Exc

lud

ing

: Las

er m

arki

ng. L

entic

ular

arra

ys. A

esth

etic

s. 1

0mm

dep

th li

mit.

VIS

ION

1 se

c/di

agon

al in

ch.

100m

m r

esol

utio

n.

$20B

n gl

obal

mar

ket.

Lo

w /

Med

ium

siz

e

Ap

plic

atio

ns

in:

Cel

l/tis

sue

–m

ater

ial i

nter

actio

n

in m

edic

al d

evic

es.

↓ a

ir/w

ater

res

ista

nce

Hyd

roph

ilic/

Hyd

roph

obic

–

mic

roflu

idic

s

Mec

hani

cal s

tren

gthe

ning

.

Ligh

ting/

disp

lays

MIL

ES

TO

NE

2

•CM

2 co

mpa

tibili

ty

•Ide

ntify

cont

acts

/sta

keho

ld

ers/

key

opin

ion

lead

er

•Dev

elop

pro

cess

with

cur

rent

lase

r

SoA

. C

ompa

re to

othe

r co

mpe

ting

tech

niqu

es.

Sta

te o

f A

rt(2

01

4)

Sh

ort

ter

m (

20

16

)

Med

ium

-ter

m (

20

19

)

Lo

ng

-ter

m (

20

24

)

Vis

ion

SY

ST

EM

HA

RD

WA

RE

Opt

imis

ed s

hort

pul

se

lase

rs (

pow

er/r

elia

bilit

y).

Hig

h po

wer

UV

lase

rs.

•Im

prov

ed b

eam

shap

ing/

capa

bilit

y.

•Dyn

amic

par

alle

l

proc

essi

ng

•Hig

h sp

eed

•Syn

chro

nisa

tion

of

scan

ners

/sta

ges

for

2D.

•Sur

face

pro

file

imag

ing

(inte

grat

ing

curr

ent

tech

nolo

gy

FIR

ST

AC

TIO

NS

•Lar

ge a

rea

mod

ifica

tion,

eg

10

cm2 .

•Whe

re s

urfa

ce

func

tiona

lity

is

adde

d.

MIL

ES

TO

NE

1

•Hig

h pr

f1kw

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r.

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h sp

eed

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ners

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l.

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mic

al/

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proc

esse

s la

ser

polis

hing

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ES

TO

NE

3

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capa

bilit

y bu

t

↑ c

ost.

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uce

cost

s of

(lase

r) p

roce

ss.

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elop

to “

real

”

3D/2

D s

yste

ms

MIL

ES

TO

NE

4

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capa

bilit

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↓ c

ost h

igh

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ut.

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relia

ble

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RD

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mul

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eria

ls p

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ssin

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l tim

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nsin

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& s

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plex

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for

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kpie

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l tim

e fe

edba

ck

cont

rol


Page 29 of 49

Figure 16: E-version of Completed Roadmap template for Micro-manufacturing.

Ap

plic

atio

n:

Mic

rom

anu

fact

uri

ng

Par

tici

pan

ts::

M G

ow

er, C

Wes

t, N

orm

an, H

all,

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coln

, Osb

ou

rne,

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er, L

i,

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rsle

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MM

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and

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ture

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at’s

IN:

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hat

is t

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plic

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n?

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at’s

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ST

EP

2:

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k to

Key

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ust

ry D

rive

rs /

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ds

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EP

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adm

ap fo

r th

e

Ap

plic

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a. D

emo

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rs c

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n /

step

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tow

ard

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rtte

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ium

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on

stra

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ion

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b. R

equ

ired

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dw

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ance

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ew la

sers

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ey T

ech

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ies

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ser B

eam

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ent

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ater

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er

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ucc

ess

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/ K

no

wle

dg

e G

aps

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EP

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Key

R&

D p

rio

riti

es

4. K

ey R

&D

pri

ori

ties

Wh

at c

an h

elp

pro

gres

s?

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lers

? S

tren

gth

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at c

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ind

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rier

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eakn

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hy?

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ow

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eria

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nsf

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em a

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ntr

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gle

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ers.

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ket.

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inin

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00

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nTh

ick

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3 m

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igh

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Rat

e.

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rces

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ano

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emto

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dis

pla

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r ??

?. T

ou

ch

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tom

oti

ve (

fuel

in

ject

ors

). S

enso

rs.

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ical

. M

ems.

6-7

UK

su

pp

liers

th

at

can

pro

vid

e P

S la

ser

syst

ems

(on

e b

ein

g C

oh

eren

t Sc

otl

and

).

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a m

assi

ve

inte

rnat

ion

al m

arke

t.

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iatu

risa

tio

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h

pre

cisi

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. M

ore

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ion

. En

viro

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edic

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ual

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igh

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27


Page 30 of 49

Figure 17: Consolidated Roadmap for Micro-manufacturing.

Mic

ro-m

anu

fact

uri

ng

Incl

ud

ing

:M

ater

ial t

rans

fer.

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tem

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gle

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pplic

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:

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ro e

lect

roni

c di

spla

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olar

, Tou

ch s

cree

n, A

utom

otiv

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uel i

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enso

rs, M

edic

al,

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s

Exc

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: CW

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itive

mar

ket.

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ning

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ION

1-10

0 m

in c

ritic

al d

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sion

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ck m

ater

ial (

<3

mm

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ition

equ

ipm

ent,

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ners

,

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spe

ed r

obot

ics,

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rs

nsec

/pse

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ched

to

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. H

igh

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e.

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sup

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rs th

at c

an

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ve in

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nal

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ket.

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ES

TO

NE

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psec

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16

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ium

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19

)

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m (

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24

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SY

ST

EM

HA

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RE

X E

/2 (

half

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F

Sx1

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→ p

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(Wid

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part

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put:

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and

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onve

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/5 a

nd x

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proc

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mon

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x R

(a

hund

red

times

the

relia

bilit

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Page 31 of 49

4.2 Links of Shortlisted Application Areas to Market Drivers

When considered collectively, the four Application areas link well to each of the top five market needs and drivers and reasonably well to all the rest. It is perhaps particularly noteworthy that “Enhanced/ Integrated laser-based systems” was earlier in the day rated as being among the top ten most powerful market and industry needs. Its importance is perhaps also reflected in the identified research and development priorities, discussed in the next section, which will address this market driver.

The links of the selected Application Areas to the market needs and drivers are shown in Table 2.

Table 2: Links of the market drivers & needs to the selected laser-based manufacturing Application Areas.

APPLICATION AREA

Additive Manufacturing

including Repair

Joining materials

Surface processing

and modifications

Micro-manufacturing

MA

RK

ET

DR

IVE

RS

AN

D N

EE

DS

A New Laser Processing / Processing Machine Capabilities

B Reducing Manufacturing and Laser System Costs

C Automation and Intelligence to Enable Product Customisation

D New / Improved Industrial Lasers - More power, lower cost

E Environmental / Energy Costs & Consumption

F Enhanced / Integrated Laser-based Systems

G New AM capability

H Improving Knowledge Transfer

I Ability to produce Multifunctional structures

J Flexible Manufacturing

K Mobile / Portable Laser Systems

L Economic, Political & Regulatory Changes in Macroeconomic Environment

M Ability to process Composites & Complex Materials

N Enabling higher manufacturing / processing speeds

O Improving Product Reliability & Consistency

P Miniaturisation

Q Just in Time Manufacturing & Lead time Improvement

R Requirement for Better Fuel Efficiency

S Social Changes

T Skills and Labour Requirements

U Improved Yield

V High precision manufacturing


Page 32 of 49

5.0 Technologies and Required R&D Priorities

5.1 Research and Development Priorities

The following technologies and R&D activities were deemed most important by the participants to support the development plans of the laser-based manufacturing applications as well as strengthen the UK research capability as a whole:

Improve the fundamental understanding of laser-material interaction and eliminate the “black art” currently associated with laser-based manufacturing processes. In particular, understanding and controlling material and / or join distortion, heat profiles, gas shielding, microstructure and residual stress for a range of materials were regarded as very important. Furthermore, research in material science of dissimilar or advance materials was also considered a critical long term goal.

Process output monitoring, analysis and control were regarded as of key importance in this field. This incorporates process modelling, porosity control, process development for high average power applications, processing of multiple materials as well as process synchronisation and / or parallel processing. Ultimately, full integration of different laser processes and subsequent integration of laser processes with other manufacturing processes is required to advance this area. This needs to incorporate sensors to enable the development of faster response systems by a factor of 10 or more with the ability of real-time data processing and control.

Better or new lasers and laser systems are required for the new manufacturing processes and applications. This includes, faster (picosecond and femtosecond), higher power, lower cost, more reliable lasers capable of continuous operation. Integration of lasers into machines, tools and equipment is also required and this needs to be supported by an improvement of the quality and availability of laser consumables.

Beam delivery and control is currently an issue for many laser-based manufacturing processes. Beam shaping can inadvertently affect precision and speed. Better beam characterisation, diagnostics and manipulation, possibly with the inclusion of adaptive optics are necessary to allow wider use of lasers in manufacturing.

Development of sophisticated, high speed scanners and scanning systems is also a priority in the field.

Table 3 shows each of the R&D priorities that emerged from the workshop and their applicability/relevance to the four laser-based manufacturing applications.


Page 33 of 49

Table 3: Relevance of R&D priorities to Short listed Application Areas

Laser-based Manufacturing Application Areas

Ad

dit

ive

man

ufa

ctu

rin

g

Join

ing

mat

eri

als

Mic

ro-

man

ufa

ctu

rin

g

Surf

ace

pro

cess

ing

Key

Re

sear

ch P

rio

riti

es

Process monitor control x x x x

High power short wavelength lasers x x x x

Sensors and control x x x x

Beam characterisation & diagnostics. Beam manipulation, beam shaping.

x x x x

Key need for very high speed scanners and control of scanners. Creation of scanning systems for m-features.

x

x x

Close loop system x x

Materials science understanding and fundamental science of welding especially around material melting dynamics.

x x

Elimination of black art x x x x

Modelling x x

Expert systems x x

Shielding system (BP). x x

Laser peening x

x

Laser polishing – for improving surface of additive manufacturing parts.

x

x

Development of lower cost lasers for processing and surfacing. Reliable low cost ps fs lasers.

x x


Page 34 of 49

5.2 Strengths, Weaknesses, Knowledge Gaps and Enablers

The main strengths and weaknesses as well as the knowledge gaps of the UK laser sector were captured during the workshop. The UK appears to be strong in solid state and fibre laser technologies, with highly-rated academic laser research and expanding commercial laser companies. The UK is also strong in other research activities that are required to develop the new generation lasers and laser systems such as optics, modelling and simulation, sensors, analysis and monitoring systems.

There is good international market demand for lasers and a well-established supply chain in the industry of component manufacturers, laser system integrators and laser users who can continue to support current and future developments in this sector.

The weaknesses identified were mainly around shortage of engineers with some certain technical and engineering skills required for the next generation of lasers and materials processing, including areas related to system integration. Inadequate capability and knowledge related to laser manufacturing process improvement was also raised as an issue. The low UK market take-up/demand for laser-based systems in manufacturing (e.g. compared to Germany) which is evident across diverse areas of UK industrial engineering appears to indicate a low level of appreciation of the commercial benefits of these technologies. Also, the weak position of UK industry in the supply chain for powders required for innovation in additive manufacturing was identified as a risk. Finally, laborious and time consuming regulations in the medical sector were also seen as a weakness to properly exploit lasers and laser technology in this large sector.

Key knowledge gaps mentioned included suitable beam analysis technology to enable the development of improved beam delivery and control in manufacturing processes. Understanding in detail the process capability and laser-material interactions is also seen as very important and one of the key research priorities identified in the previous section. New approaches and innovations are required to progress this area with stronger collaborations and links both with the academic community and industry engineers. Better engineering standards need to be

established to allow tighter control of laser-based manufacturing processes.

Finally, the ‘enablers’ discussed were predominantly around economic support or incentives i.e. help on exporting since 95% of the market demand is outside the UK, availability of investment especially for capital equipment and better public funding for application and demonstration projects (Technology Readiness Levels 4-7). Finally better knowledge transfer between industrialists, academics and engineers was seen as important in speeding up progress in this field.

Table 4 summarises the UK strengths and weaknesses, knowledge gaps and potential enablers, as derived from the Workshop process.


Page 35 of 49

Table 4: Strengths Weaknesses, Knowledge Gaps and potential enablers for UK laser-based Manufacturing

UK Strengths UK Weaknesses

Solid state and fibre laser technologies.

Research on optics, modelling and simulation, sensors and analysis and monitoring systems.

Good international market demand for lasers and laser systems.

Well-established supply chain in the laser industry of component manufacturers, laser system integrators and laser users.

Shortage of relevant technical and engineering skills required for the next generation of lasers and materials processing, especially around system integration.

Low capability and knowledge on process improvement.

Very small UK market demand for lasers and laser systems.

UK position in the powder supply chain.

Heavy regulations in the medical sector.

UK innovation lacking behind this of other countries.

Knowledge Gaps

Beam profiling software to enable the development of improved beam delivery and control in manufacturing processes.

Detailed understanding of process capability and laser-material interactions.

“Thinking outside the box” approaches to speed up innovations in the sector.

Designing and establishing engineering standards to achieve better control of laser-based manufacturing processes.

Enablers

Economic support or incentives i.e. exporting, finance for capital equipment and public funding for application and demonstration projects.

Collaboration and knowledge transfer between industrialists, academics and engineers.

6.0 Consultation with UK Community

Recognising that the Roadmapping Workshop day had allowed direct involvement from only a limited number of attendees, a UK-wide Consultation exercise was organised with a view to extending this more broadly across the community. The basis of the Consultation was the Draft (Interim) Roadmap-2014 Report which, along with a targeted Questionnaire (see Appendix E) which was circulated by email to more than 120 colleagues in industry, academia and government. Despite the relatively short consultation window, and its inconvenient timing (during the August holiday season) more than 50 responses to the Consultation were received.

These responses have been analysed and form the basis of this section.

The input to the consultation analysis also includes relevant opinions and comments expressed by members of both consultative bodies that oversee the Centre (CIM-LbPP), namely the Steering Group and the Industrial Advisory Group, whose joint meeting happened to occur (conveniently) at a time when the draft Roadmap Interim Report was available for review.

6.1 Summary of Consultation Responses In general, the consultation responses indicated broad (and even strong) agreement with the outcomes from the Roadmapping Workshop as outlined in the Interim Roadmap Report. There were no serious disagreements expressed and few negative comments.

The Consultation produced two important additional suggestions/conclusions, as follows:

1. The most frequently recognised ‘additional issue’ identified in the consultation responses, and articulated in different ways in more than 25% of the responses relates to the perceived


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(low) level of adoption of laser-based production technologies across UK manufacturing industry. A common belief is that utilisation of laser processes in UK manufacturing is lower than in other countries in the top ten of global manufacturing economies, and that greater appreciation of the benefits such technologies offer e.g. in reducing costs, increasing quality and versatility would, in many cases increase the competitiveness of UK products.

Such comments include the following:

“. . . biggest challenge will be using this report to get the message across to the manufacturing sector that laser based manufacturing processes offer solutions to many of the challenges that manufacturing is facing”

“The key element of increasing up-take of laser based processing by UK industry requires further attention. The identified application areas certainly provide opportunity but a strategy for generating more pull from manufacturing to use more laser processing is still required and is not really addressed through the R & D priorities.”

“. . . the lack of investment in laser technology in the UK stems from the fact that the general engineering community is not aware of the potential benefits of laser materials processing.”

“. . . need to demonstrate more broadly to potential customers/designers“.

“In general ‘encouraging and educating’ current manufacturers about laser based processing will not be enough. New mittelstand companies set up with laser based processing at their core need to be fostered and created.”

“The report should be disseminated as widely as possible within the UK . . . with a focus on UK government / EU agencies who formulate policy for manufacturing”

Thus, there appears to be a broad-based and strongly-expressed view that in addition to the technical areas proposed for further research and development as outlined in Section 5, the need also exists for socio-economic research to underpin future strategic planning efforts aimed at driving increased productive exploitation of laser-based technologies in all relevant sectors of UK manufacturing industry.

2. The second significant point raised was the suggestion (accepted) that a well-structured Short Version of the Roadmap-2014 Report (4-pages) is necessary as the principal vehicle for addressing policy makers and other stake-holders.


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7.0 Summary and Conclusions

A foresighting procedure to develop a UK Roadmap for Laser-based Manufacturing Applications has been organised and sponsored by the Association of Industrial Laser Users and the EPSRC Centre of Innovative Manufacturing in Laser-based Production Processes. The core of the activity was a 1-Day Workshop held in March 2014, which brought together 29 participants from UK industry, academia and the public sector to explore market and industry needs, prioritise relevant applications and assist in developing R&D priorities for the UK. The Workshop was conducted using methodology developed by the Institute of Manufacturing (IfM) at Cambridge University and facilitated by staff from the IfM led by Dr Nicky Athanassopoulou.

A preliminary Report [6] providing a detailed documentary account of the Workshop proceedings, including accurate e-versions of the parallel sets of work-charts developed by the participants during the workshop. An Interim Roadmap Report drawing heavily on [6] was prepared and used, along with a focussed Questionnaire [Appendix E] as the basis of a community Consultation exercise. The Report and Questionnaire were emailed to more than one hundred active laser and manufacturing professionals, seeking their opinions on the Roadmap Interim Report and especially on the validity of the conclusions drawn, as well as providing opportunities for independent comment and analysis. Responses were received from more than 50 colleagues, and in the light of this new information, the current Final Report has been compiled.

Among other issues, it was judged that laser systems can and should play an extremely important role in meeting current and future market requirements across a range of areas including processing of advanced, dissimilar or brittle materials, reducing manufacturing costs, increasing manufacturing speeds and reducing environmental impact from industrial activity.

The Report identifies FIVE topics, including both technical and socio-economic areas which have been judged deserving of the highest levels of future attention and investment.

Technical Priorities: On the purely technical side, four laser-based manufacturing processes were selected as top technical priorities due to their potentially widespread impact on a range of different markets from medical and aerospace, to microelectronics and transport.

These are (not in order of importance) as follows:

1. Additive Manufacturing, including Repair

2. Joining materials including both thin and thick, similar and dissimilar materials

3. Surface processing and modification

4. Micro-manufacturing

In prioritising future R&D investment needs, there was recognition of the need for a more structured focus on achieving deeper, quantitative understanding of laser material interaction science as core underpinning for the realisation of more predictable and transferable laser-based manufacturing processes. The need exists for such an approach to embrace (but not exclusively) manufacturing applications of advanced, dissimilar and brittle materials. A further essential requirement is the development of improved laser-process monitoring techniques with reliable associated hardware that can be integrated into automated machines.

The continuing need for sustained R&D at all levels in the in the supply chain for laser-based production machines was also recognised. On the hardware component side, R&D is required that addresses both fundamental laser device technology and improved techniques and components for laser beam manipulation including high-speed, real-time (adaptive) control. In addition, there was frequent mention of the need to incorporate increased levels of automation in laser tools and machines, while reducing cost of ownership through increased productivity and reduced environmental impact.


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An additional (non-technical) research priority must be added which emerged strongly from the UK community consultation exercise, and which resonates with the longer-term objective of the joint AILU/CIM-LbPP initiative as outlined in the Introduction to the this report.

Socio-economic Priority 5. The need exists for socio-economic research to underpin future strategic planning efforts

aimed at generating increased market pull from manufacturing companies, linked to a coordinated national programme (e.g. market research, advertising, education technology demonstrators) driving towards increased productive exploitation of laser-based technologies in all relevant sectors of UK manufacturing industry.

The Roadmap is viewed as a first step down the path to developing a National Strategy for Laser based Manufacturing. The overall aim of which is to generate a coherent strategy document for the UK that will be used to influence UK policymakers, trainers and educators, and industry. The key strategic goals are to stimulate the implementation of laser-based manufacturing processes across a much broader range of UK manufacturing industry, and to develop suitable support mechanisms to support and further develop a small but very successful laser manufacturing and machine integration manufacturing industry in the UK.


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8.0 References

1. Farnham AILU Meeting Farnham Report ‘First steps of a strategy for Laser Materials Processing in the UK:

Report of the UK Laser Materials Processing Strategy Workshop Farnham Castle, Surrey 21 & 22 February 2012’ Published by the Association of Laser Users (AILU) August 2012. http://www.ailu.org.uk/laser_technology/the_laser_user_magazine/articles/6722.html

2. Main Photonics21 website at: http://www.photonics21.org/ Particularly see “Photonics Strategic Multiannual Roadmap” (April 2013), and outputs of: - Work Group II, ‘Industrial Manufacturing and Quality’, pp35-41, and - Work Group VI ‘Design and Manufacture of Components and Systems’ pp70-83 at: http://www.photonics21.org/download/Brochures/Photonics_Roadmap_final_lowres.pdf 3. ‘The Future of Manufacturing: An Era of Opportunity and Challenge for the UK’ Foresight Report from the

UK Government Office of Science, London (November 2013). Main report and summary documents. https://www.gov.uk/government/uploads/system/uploads/attachment_data/file/255923/13-810-future-manufacturing-summary-report.pdf

4. Factories of the Future - Multi‑annual roadmap for the contractual PPP under Horizon 2020’ Prepared by

European Factories of the Future Research Association – a MANUFACTURE initiative and Published by European Commission, Luxembourg: Publications Office of the European Union, 2013, ISBN 978-92-79-31238-0, doi:10.2777/29815.

http://www.effra.eu/attachments/article/129/Factories%20of%20the%20Future%202020%20Roadmap.pdf See also:

http://www.effra.eu/index.php?option=com_content&view=category&layout=blog&id=85&Itemid=133

5. ‘Harnessing Light: Optical Science & Engineering for the 21st Century’ US National Academies Press, 1998. http://www.nap.edu/catalog.php?record_id=5954

and

‘Optics and Photonics: Essential Technologies for Our Nation’ US National Academies Press, 2013. http://www.nap.edu/catalog.php?record_id=13491

6. Report on UK Roadmapping Workshop of Laser-based Manufacturing Applications 04 March 2014 Dr Nicky Athanassopoulou, IfM Education and Consultancy Services, Cambridge, 2014IMI for Integrated Photonics Manufacture

7. Recent decision in the USA to invest more than $200M in a new Integrated Photonics Manufacturing Institute http://www.whitehouse.gov/the-press-office/2014/10/03/fact-sheet-president-obama-announces-new-manufacturing-innovation-instit

http://www.ailu.org.uk/laser_technology/the_laser_user_magazine/articles/6722.html

http://www.photonics21.org/

http://www.photonics21.org/download/Brochures/Photonics_Roadmap_final_lowres.pdf

https://www.gov.uk/government/uploads/system/uploads/attachment_data/file/255923/13-810-future-manufacturing-summary-report.pdf


http://www.effra.eu/attachments/article/129/Factories%20of%20the%20Future%202020%20Roadmap.pdf

http://www.effra.eu/index.php?option=com_content&view=category&layout=blog&id=85&Itemid=133

http://www.nap.edu/catalog.php?record_id=5954

http://www.nap.edu/catalog.php?record_id=13491

http://www.whitehouse.gov/the-press-office/2014/10/03/fact-sheet-president-obama-announces-new-manufacturing-innovation-instit

http://www.whitehouse.gov/the-press-office/2014/10/03/fact-sheet-president-obama-announces-new-manufacturing-innovation-instit


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Appendix A: Workshop Attendee List

NAME ORGANISATION IN

DU

STR

Y

Adam Brunton M-Solv

Simon Fung AWE

Simon Gardiner Airbus

Mark Greenwood JK Lasers

Mike Green The Association of Industrial Laser Users

Paul Goodwin Laser Cladding Technology

Malcolm Gower Nanophoton Technologies

Clive Grafton-Reed Rolls Royce Ltd

Denis Hall Rofin-Sinar UK Ltd

Paul Hilton TWI

Andrew Kearsley Oxford Lasers

Robert Lamb Selex Galileo

John Lincoln Harlin/Photonics CIM

Nick Longfield Manufacturing Technology Centre

AC

AD

EMIA

-

-

GO

VER

NM

ENT

FAC

ILIT

ATO

RS

-

-


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Appendix B: Guidance Notes for pre-Workshop Homework

UK Roadmapping Workshop Laser-based Manufacturing Applications

Tuesday 04 March 2014

Workshop Facilitators: Dr Nicky Athanassopoulou (Institute for Manufacturing, Cambridge University)

Mr John McManus (Institute for Manufacturing, Cambridge University)

WORKSHOP AGENDA

09.45 Arrival – Coffee

10.15 Welcome, Introduction and Overview

10.30 Individual Presentations on Drivers, Applications All

11.45 Prioritisation Criteria - Dr Athanassopoulou

12.00 Prioritisation of most important Applications All

12.30 Selection of top 5-8 Applications All

13.00 LUNCH

13.45 Break-out Group Work: Explore the selected applications Groups

15.30 Identify/Understand the technologies to be developed/integrated Groups

16.30 Feedback and Review All

17.30 Close

UK Roadmapping Workshop: Laser-Based Manufacturing Applications

Introduction One of the main outcomes of the Workshop on Laser Materials Processing (LMP) held at Farnham Castle in February 2012 [2] was a widely-shared recognition of the need to produce a Roadmap (relating to both laser-based manufacturing applications and required hardware), which is relevant to UK researchers, manufacturing-user and technology-supply companies, as well as providing an evidence-base for strategic planners and UK funding agencies.

With the aim of achieving this goal, the Association of Laser Users (AILU) has partnered with the recently-launched EPSRC Centre for Innovative Manufacturing (CIM) in Laser-Based Production Processes. Resources have been pooled to provide leadership and organisational structure to coordinate inputs from both industrial and academic sectors of the UK community in laser-based manufacturing applications with the aim of generating such a Roadmap. In addition, we are pleased to acknowledge the support of the Department for Business, Innovation and Skills (BIS) and the Electronics, Sensors and Photonics Knowledge transfer Network (ESP KTN).


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Objectives The primary purpose of the Roadmap is to identify new and evolving manufacturing applications where laser processing may play a significant enabling role, e.g. for high-value-added components fabricated from new/mixed engineering materials, or relating to new production techniques.

In addition, the aim is to identify relevant areas where future research and development would be required to facilitate laser-based solutions to such production needs, for example in new laser-material process science and technology, new or enhanced laser source development, beam manipulation and delivery and integration/control issues.

Consequently, the Roadmap output should provide foresight information relating to one or more of the following:

1. new or enhanced manufacturing processes and/or applications:

2. new or enhanced laser-based manufacturing systems;

3. new or enhanced key system components (e.g. new lasers)

UK industrial laser source and system manufacturers continue to suffer from a relatively weak home market, driving them to export typically >80% of their products. Indeed, it is relevant to note (and react to) the fact that photonics-based technologies were nearly-completely absent from the view of the future of UK manufacturing produced in a report [1] produced in late 2012 by a Foresight Team working with the UK Government Office for Science. So, whilst fully recognising the global nature of the business an important objective is to alert UK manufacturers and government industrial policy makers to the powerful enabling features of laser-based processes in manufacturing across diverse sectors of industry, and particularly at the high-added-value end of the market.

One-Day Roadmapping Workshop A critical element in the formulation of a UK Roadmap covering Laser-based Manufacturing Applications is the 1-Day Roadmapping Workshop scheduled to take place on 04 March 2014 at the BIS Facility in Victoria St, London. This Roadmapping Workshop has been planned in close consultation with the Institute for Manufacturing (IfM) at Cambridge University, and particularly with Dr Nicky Athanassopoulou, who will provide facilitation on the day.

The experience of IfM professionals with this type of Workshop strongly suggests a limit for on-site participation of about 30, and this matches the available facilities which are provided by BIS. Faced with this difficult selection task, the organising team has sought to produce an attendee list which is dominated by industrial colleagues (>4:1 of industry/academia), has a good balance between users and those in the hardware supply chain, and includes a good experience balance.

Moreover, recognising that with such a small number of delegates there will be many with much to offer the Roadmap construction process who will not be present on the day, we are including non-attendees and attendees alike in a pre-Workshop ‘Homework Stage’, so that a significantly larger fraction of the UK LMP community can contribute. Further information including guidance notes and pro-forma for the pre-Workshop submission are provided below.

We are not, of course, starting from scratch. In addition to the Farnham Report [2] there has been, for example, the Europe-wide Photonics21 Roadmaps [3], to which many in the UK community have contributed.

References 1. ‘The Future of Manufacturing: An Era of Opportunity and Challenge for the UK’ Foresight Report from UK Government

Office of Science, London (November 2013). Both Main Report and Summary Documents are available at:. https://www.gov.uk/government/uploads/system/uploads/attachment_data/file/255923/13-810-future-manufacturing-summary-report.pdf

2. Farnham Report ‘First steps of a strategy for Laser Materials Processing in the UK: Report of the UK Laser Materials Processing Strategy Workshop Farnham Castle, Surrey 21 & 22 February 2012’ Published by the Association of Laser Users (AILU) August 2012.

3. Main Photonics21 website at: http://www.photonics21.org/ Particularly see “Photonics Strategic Multiannual Roadmap” (April 2013), and outputs of:

- Work Group II, ‘Industrial Manufacturing and Quality’, pp35-41, and - Work Group VI ‘Design and Manufacture of Components and Systems’ pp70-83

at: http://www.photonics21.org/download/Brochures/Photonics_Roadmap_final_lowres.pdf



http://www.photonics21.org/

http://www.photonics21.org/download/Brochures/Photonics_Roadmap_final_lowres.pdf


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Appendix C: Workshop Programme Agenda

09.45 Arrival

10.15 Welcome, Introductions and Overview

10.30 Individual presentations on Drivers, Applications All

11.45 Prioritisation of the most important applications All

12.30 Selection of top 5-8 Applications All

13.00 Lunch

13.45 Break-out Group Work: Explore the selected applications In Groups

15.30 Identify/Understand the technologies to be

developed/integrated In Groups

16.30 Feedback and Review All

17.30 Close

• Identify what applications are emerging in lasers, processes and materials

• Identify what type of lasers or associated equipment will be required by industry in the future

• Identify the capabilities and underlying technologies that will be needed to deliver future laser systems and applications.

• Select and explore applications effectively

• Promote a consensual approach to application prioritisation leading to practical action plans

Workshop Objectives


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Appendix D: Attendee Groups for Detailed Exploration of Selected Application Areas

Additive Manufacturing

including Repair

Joining materials including both thin

and thick, similar and dissimilar materials

Surface processing and modifications

Micro-manufacturing

Clive Grafton-Reed Mark Goossens Jagjit Siddhu Louise Jones Alastair Wilson

Simon Fung Paul Hilton Robert Lamb Nick Longfield Neil Main Stewart Williams

Ric Allott Karen Brakspear Adam Brunton Mike Green Mark Greenwood Duncan Hand Roy McBride

Daniel Esser Malcolm Gower Denis Hall Lin Li John Lincoln Andrew Kearsley Steve Norman Mike Osborne Craig West


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Appendix E: Post-Workshop Community Consultation Questionnaire


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