Improving processes for high-rate, low-cost manufacture

The manufacturing industry is facing ever-rising material costs, higher expectations on sustainability, and the constant need for higher rates of production.

Composite manufacturing is at the forefront of providing the latest technological answers to these problems. But it’s a highly complex area, and it can be hard to keep on top of the latest innovations.

Here at the AMRC we combine years of industry expertise with the latest world-class technology to find new ways to improve processes, reduce costs and increase sustainability. We have expertise not only in the latest techniques in composite manufacturing but also an extensive understanding of the demands on tooling, so we know how to make changes that work on the shop floor.

We work with companies of all sizes to tackle their production problems, whether it’s reducing costs, increasing production rates, or creating less waste. With our extraordinary machines and the best engineering minds at your disposal, the only limit is your imagination.

Lighter, cheaper, less wasteful

Composite materials offer a wealth of advantages. You create an item to the specific shape and properties you need in a single process. It’s versatile and it means less waste material.

  • Efficiencies through lightweighting: In aerospace, a kilo less weight on an aeroplane saves 180 kilos of fuel and 600 kilos of carbon dioxide per year.
  • Streamlined processes: Composite moulding processes can produce very complex parts in one go, reducing the need for additional machining.
  • The latest techniques: We have the knowledge and technology for pioneering techniques like dry fibre composites and thermoplastics.

We are at the forefront of the digital assessment of composite manufacturing. By embedding modern sensors and an ability to adapt processes live means we can help you identify defects early to eliminate costly scrap material. We can also reduce manufacturing time and ensure the high-volume production required by the aerospace and automotive sectors.

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Key capabilities

We have the expertise and equipment to help you transition towards more sustainable thermoplastic composite materials and corresponding manufacturing processes. This includes the ability to configure and manufacture thermoplastic pre-preg tape to bespoke applications. We can help you make the most of this exciting technology, with government funding to help you specify your requirements to volume manufacturers.

Our automated processes can take cycle times down from six hours to 15 minutes, removing unnecessary manual work and ensuring the highest quality standards. Our open-access COMPASS facility can fully automate the high-rate manufacture of parts up to 10 metres by 3 metres. We research the latest techniques such as automated fibre placement (AFP) and filament winding as automated manufacturing processes.

We can replace expensive pre-preg materials with bespoke woven dry fibre, making our processes more efficient and allowing high-volume production of large, complex parts. Our Jacquard loom can create 3D woven structures, giving you high production rates with properties not available through any other process. We also work on tailored fibre placement (TFP), a low-cost and high-rate process for creating bespoke fibre architectures and carbon fibre structures.

Machining of composites requires very specific cutting tools and techniques. We work with both tool suppliers and end users to compare and contrast the performance of different processes. With our extensive experience in drilling, edge trimming, and surface machining composites, we can help you optimise these processes to ensure quality and meet your cost requirements.

We embed sensors and fibre optics in components to monitor their health throughout the manufacturing process, allowing for real-time process updates and reducing waste by providing accurate information on the stresses materials can face.

Make composites work for your business

We work with businesses of all sizes to find solutions to their challenges. Our unique blend of strong academic research and significant industry experience within the team means we can have a big impact on your processes — and your bottom line.

We have the facilities and expertise to create an entire manufacturing process, starting with a design right through to a moulded and fully machined finished component.

From automating your production line to finding the right cutting tools, there are many ways we can improve how you do things. We also undertake research to push UK industry forward, concentrating on the biggest challenges like sustainability and supply chain resilience and the latest techniques from thermoplastics to automation.

Discover what composites can do for you

Speak to our experts about using the latest composites technology to improve your processes.

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