Additive manufacturing has the potential to impact on the life of everyone through the manufacturing of complex parts in a single process. Additive manufacturing involves building parts layer by layer, rather than cutting away material which happens with conventional manufacturing processes. To fully realise the potential of additive manufacturing new ways of undertaking engineering design need to be developed. The conventional way of educating engineering designers limits the opportunities additive manufacturing offers. The overall aim of this project is to develop new design processes based on human development for additive manufacturing. There are many similarities between human development and additive manufacturing and this project will exploit these similarities to develop new design rules. In the project a study will be undertaken to understand how the medical device industry currently designs implants and determine their uptake of additive manufacturing processes and the barriers to using the technology. The analogy between human development and additive manufacturing will then be investigated to help create a new set of design rules for additive manufacturing. Finally the new design rules will be tested. The main output from this project will be a new set of design rules for additive manufacturing that can be used to produce cost-effective parts.

X-ray Computed Tomography (XCT) is a scanning technique that enables full 3D visualisation and interrogation of internal and external geometries. It has become popular within industry (particularly manufacturing) and academic research as it enables us to see more than ever before at a variety of length scales and is completely non-destructive. The time taken to obtain this wealth of data is prohibitive to a number of applications with a single scan taking tens of minutes, up to a few hours. The equipment outlined in this proposal will enable high-resolution scans in tens of seconds, and even faster with some fundamental research. This is a UK first that will generate a wealth of scientific advancement. There have been a small countable number of "dynamic" experiments using lab based XCT scanners where a sample such as a novel material is sequentially loaded (e.g. compression) and scanned at each loading step. Here one can observe the changes in the material through time, identifying failure mechanisms, highlighting potential manufacturing improvements and aids in determining material properties. The reason for so few studies is that the number of scans required can lead to acquisition time of days. The substantial gain in speed with this equipment will reduce the total scan time to a matter of minutes with a continuously acquired dataset. The sample can then be evaluated at discrete points in time, and concentrate around the critical onset of failure observed. Scientific advancement in the development of new polymers, ceramics and metal alloys will be considerably accelerated with this unique characterisation capability. Manufacturing applications are often limited to a few high-value components because of the time taken to scan. The significant step change in speed will allow for high-throughput scanning that is desirable within the manufacturing line. This is the first step in a major revolution that will require big data analytics powered by machine learning algorithms to deliver accept/reject decisions in a reasonable time scale. Together this will be a driver for change in achieving 100% inspection of large component batches, at high resolution and at relevant cycle times.

Summary: A novel laboratory scale continuous hydrothermal flow synthesis (CHFS) system has been developed for the controlled synthesis of inorganic nano-materials (particles <100nm) with potential commercial applications from sunscreens and battery materials to fuel cell components and photocatalysts. The CHFS system has many advantages; it is a green technology (using supercritical water as the reagent), which utilises inexpensive precursors (metal nitrate salts) and can controllably produce high quality, technologically important functional nano-materials in an efficient single step (or fewer steps than conventionally). This project seeks to move the existing laboratory scale CHFS system (developed over the past few years at QMUL) towards a x10 pilot scale-up (nano-powder production of up to 500g per 12h depending on variables). The proposed research will initially compare the ability to control particle characteristics of the CHFS system at the laboratory scale over a large range of process variables (flow rates, temperatures, pressures, etc), building full operational envelopes that will describe reactor variables versus particle properties for each material. In particular, we will utilise process analytical technology (PAT)and the data will help develop univariate and multivariate understanding of the temporal operational spaces and interactions between process variables and product quality. PATand chemometrics incorporated with combined computational fluid dynamics modelling of hydrodynamics/mixing and population balance modelling of particle size evolution via nano-precipitation will be used to study alternative nozzles designs and other potential bottleneck factors. This will lead to a generic strategy for scaling up and controlled manufacture of nanomaterials with consistent, reproducible and predictable quality. The scale up quantities of nano-powders from the pilot plant will allow industrial partners to perform prototyping or comprehensive commercial evaluation of nano-powders in a range of applications which they have hitherto not been able to conduct due to lack of sufficient high quality material. Importantly, the know-how acquired on the project and the proposed feasibility studies will reduce the risk and commercial barriers for industry that might consider building a larger industrial scale CHFS plant in the future.

Summary: A novel laboratory scale continuous hydrothermal flow synthesis (CHFS) system has been developed for the controlled synthesis of inorganic nano-materials (particles <100nm) with potential commercial applications from sunscreens and battery materials to fuel cell components and photocatalysts. The CHFS system has many advantages; it is a green technology (using supercritical water as the reagent), which utilises inexpensive precursors (metal nitrate salts) and can controllably produce high quality, technologically important functional nano-materials in an efficient single step (or fewer steps than conventionally). This project seeks to move the existing laboratory scale CHFS system (developed over the past few years at QMUL) towards a x10 pilot scale-up (nano-powder production of up to 500g per 12h depending on variables). The proposed research will initially compare the ability to control particle characteristics of the CHFS system at the laboratory scale over a large range of process variables (flow rates, temperatures, pressures, etc), building full operational envelopes that will describe reactor variables versus particle properties for each material. In particular, we will utilise on-line measurement of dynamic laser light scattering particle sizing, and at-line analytical methods. This data will help develop univariate and multivariate understanding of the temporal operational spaces and interactions between process variables and product quality. On-line sensing and chemometrics incorporated with combined computational fluid dynamics modelling of hydrodynamics/mixing and population balance modelling of particle size evolution via nano-precipitation will be used to study alternative nozzles designs and other potential bottleneck factors. This will lead to a generic strategy for scaling up and controlled manufacture of nanomaterials with consistent, reproducible and predictable quality. The scale up quantities of nano-powders from the pilot plant will allow industrial partners to perform prototyping or comprehensive commercial evaluation of nano-powders in a range of applications which they have hitherto not been able to conduct due to lack of sufficient high quality material. Importantly, the know-how acquired on the project and the proposed feasibility studies will reduce the risk and commercial barriers for industry that might consider building a larger industrial scale CHFS plant in the future.

The Centre for Doctoral Training in Tissue Engineering and Regenerative Medicine will provide postgraduate research and training for 75 students, who will be able to research, develop and deliver regenerative therapies and devices, which can repair or replace diseased tissues and restore normal tissue function. By using novel scaffolds in conjunction with the patient`s own (autologous) cells, effective acellular regenerative therapies for tissue repair can be developed at a lower cost, reduced time and reduced risk, compared to alternative and more complex cell therapy approaches. Acellular therapies have the additional advantage as being regulated as a class three medical device, which reduces the cost and time of development and clinical evaluation. Acellular technologies, whether they be synthetic or biological, are of considerable interest to industry as commercial medical products and for NHS Blood and Transplant as enhanced bioprocesses for human transplant tissues. There are an increasing number of small to medium size companies in this emerging sector and in addition larger medical technology companies see opportunities for enhancing their medical product range and address unmet clinical needs through the development of regenerative devices. The UK Life Sciences Industry Strategy and the UK Strategy for Regenerative Medicine have identified this an opportunity to support wealth and health, and the government has recently identified Regenerative Medicine as one of UK`s Great Technologies. In one recent example, we have already demonstrated that this emergent technology be translated successfully into regenerative interventions, through acellular human tissue scaffolds for heart valve repair and chronic wound treatment, and be commercialised as demonstrated by our University spin out Tissue Regenix who have developed acellular scaffold from animal tissue, which has been commercialised as a dCEL scaffold for blood vessel repair. The concept can potentially be applied to the repair of all functional tissues in the body. The government has recognised that innovation and translation of technology across "the innovation valley of death" (Commons Science and Technology Select Committee March 2013), is challenging and needs additional investment in innovation. In addition, we have identified with our partners in industry and Health Service, a gap in high level skills and capability of postgraduates in this area, who have appropriate multidisciplinary training to address the challenges in applied research, innovation, evaluation, manufacturing, and translation of regenerative therapies and devices. This emerging sector needs a new type of multidisciplinary engineer with research and training in applied physical sciences and life sciences, advanced engineering methods and techniques, supported by training in innovation, regulation, health economics and business, and with research experience in the field of regenerative therapies and devices. CDT TERM will create an enhanced multidisciplinary research training environment, by bringing together academics, industry and healthcare professionals in a unique research and innovation eco system, to train and develop the medical and biological engineers for the future, in the emerging field of regenerative therapies and devices. The CDT TERM will be supported by our existing multidisciplinary research and innovation activities and assets, which includes over 150 multidisciplinary postgraduate and postdoctoral researchers, external research funding in excess of £60M and new facilities and laboratories. With our partners in industry and the health service we will train and develop the next generation of medical and biological engineers, who will be at the frontier in the UK in innovation and translation of regenerative therapies and devices, driving economic growth and delivering benefits to health and patients