There is currently a timely opportunity to create dramatically improved green (renewable) and environmentally-friendly biodegradable materials for high volume, low load, and low cost. By manufacturing new bacterial cellulose reinforced bio-derived polymer nanocomposites, a new class of hierarchical composites with both much improved mechanical and environmental performance, as well as reduced through-life costs will be possible. The resulting product will be made completely from renewable resources, and will be totally biodegradable. We are expecting greatly improved materials for which three major applications are envisioned: fibre reinforced green nanocomposites for the automotive and construction industry and foamed nanocomposites as novel insulating materials for the packaging and construction industries.

One hundred and fifty ago, life expectancy in the UK was about 43 years. Improvements in nutrition, medicine and public health have dramatically increased this such that those born today can expect to live for over 80 years. This 150 year period is but the blink of an eye in evolution terms, and the evolution of our musculoskeletal system has not caught up with the increased life expectancy. It is therefore no surprise that musculoskeletal disorders are one of the biggest expenditures in the annual NHS budget (about £5.4bn). Our vision is for lifelong musculoskeletal health. We consider the only way to achieve this is to identify musculoskeletal problems early in life, then make small interventions to correct them before they become chronic. This preventative approach needs new technology which we will create using the equipment in the Medical Device Prototype & Manufacture Unit. We seek to manufacture early intervention implants using material that is tailored to make the surrounding bone stronger by controlling the bone strain experienced. We want to make smart instruments and implants that can measure biomarkers in synovial fluid to provide objective measures of joint health. We want to deploy new biomaterials like nanoneedles that can bypass the membrane of bacteria cells and provide anti-infection coatings on our implantable devices. We will manufacture ligament, tendon and capsule repair patches using a soft tissue 'velcro' fixation combined with functionalised surfaces that adhere to soft tissues on one side, yet provide a low friction sliding surface on the other side. We also want to better understand the ageing process of osteoporosis and the effects of bisphosphonate theory. Finally we want to perform higher fidelity laboratory testing of musculoskeletal tissues, both to understand better the pathology, but also the response of tissue to our proposed treatments. The proposed Medical Device Prototype & Manufacture Unit would enable breakthroughs in all these interrelated research themes. The powder bed fusion additive manufacture (AM) machine and 2-photon lithography AM machine allow manufacturing of porous lattice materials at the range of scales we need to create stiffness matched implants with 150 micron features down to microfluidic channels for our sensing technology and nanoneedles with sub-micron features. The nano CT scanner has a higher resolution (sub-micron) than currently available and the 3D microscope is equipped with confocal profiler with 100 nanometre resolution - these imaging instruments will allow unprecedented surface and internal imaging of pathological tissues and the response of tissues to our interventions. Our research will be conducted in an environment that will strongly encourage translation. The Prototype & Manufacture Unit will be set up with all the regulatory approval and quality control to enable us to manufacture devices from first off prototypes through to small batch production parts for early clinical safety studies. This combination of cutting edge AM and imaging equipment in an environment with strong emphasis on translation would enable us to break new ground in all our research themes and also bridge the gap between exciting laboratory testing and clinical practice.

Birefringence is a difference in refractive index that occurs along different axes in a material. In some materials this effect is intrinsic due to the atomic structure. In other materials, artificial birefringence can be induced by a mechanical stress that produces anisotropies in the material. Polarized waves travel at different velocities through the stressed regions depending on their polarization direction. This phenomenon is exploited in the well-established technique of photoelasticity, in which a model of the component of interest is made in an optically transparent plastic material and placed between polarizing optics. The induced birefringence is directly proportional to the stress experienced at a given point: contours of constant difference in the principal stresses and contours of the principal stress direction appear as fringe patterns. The technique has played a fundamental role in experimental mechanics, design and manufacturing. This project is concerned with measuring the stress-induced birefringence in materials that are opaque at visible wavelengths. We will use THz illumination between 0.3 and 1.5 THz where some fraction is transmitted through a range of non-polar materials including ceramics, plastics and composites. Measuring the stress-induced birefringence will provide information on the internal stress distribution in real components that are opaque at visible wavelengths, removing the need to model it in transparent plastic. This new unique stress visualisation technique might be considered as 'photoelesticity for opaque objects', although more accurate techniques will be used to measure the phase difference that arises between the polarized components of the illumination. Measurement from the real components also enables direct validation of numerical models. These new techniques will enable in-process control during manufacturing applications and in-service quality assurance, for a range of materials where this is not currently available, enabling step changes in the manufacturing processes used and the components that can be produced. This project will provide the underpinning research to determine if measuring stress-induced birefringence at THz frequencies is feasible. The phenomenon has not been reported in the literature. Based on the fundamental measurements of the stress-optic coefficients, THz systems will be built to measure residual stress distributions and stresses produced by direct loading in ceramic and polymer materials. Non-spectroscopic imaging at THz frequencies is not well developed, enabling novel phase measurement techniques to be implemented with single point detectors and start-of-the-art line detectors. The project brings together research expertise in optical instrumentation for industrially relevant metrology and industrial collaborators with strong track records in innovation for high value manufacturing applications.

UK has committed to an ambitious decarbonisation plan: reduce CO2 emissions by 80% by 2050 - a dramatic transformation of our energy system. Decarbonisation of the electricity sector is expected by 2030. However, meeting the targets will be impossible if decarbonisation of heat is not tackled. More than half of UK finial energy use is due to heating and cooling, which accounts for about 30% of CO2 emissions. This will require the introduction of low carbon alternatives - wind and solar energy in particular. However, such a shift poses major challenges including the imbalance between supply and demand, congestion of energy networks and in ultimate analysis the need of a more flexible energy system. Thermal energy storage (TES) has the potential to provide a solution to these challenges by capturing excess heat, time-shifting heat demand and increasing the use of renewable sources. Among the TES technologies, latent heat thermal energy storage (LHTES) is seen as one of the most promising; LHTES uses phase change materials (PCMs) and it stores/releases thermal energy during a solid to liquid phase transition of the PCM. As our ability of storing thermal energy efficiently depends significantly on the design of the heat exchangers enclosing the PCMs, a great attention has been drawn to designing new LHTES heat exchangers that outperform current state-of-the art ones. To devise the LHTES heat exchangers of the future, thinking of advanced design methods - coupled with proper manufacturing techniques - is urgently necessary. The proposed research - involving energy storage, computational methods, heat & mass transfer and manufacturing technologies - aims to i) establish a generalized route to designing thermal energy storage systems with PCMs using topology optimization methods and to ii) link the designing route with metal additive manufacturing methods. This project will therefore offer an innovative numerical design methodology and will generate experimental evidences that will allow a robust validation of the proposed method. This proposal is highly relevant for the UK research and industry in the energy sector; in particular i) It will help researchers to develop thermal energy storage systems faster and more accurately; in doing so it will enable faster deployment of low carbon technologies ii) it will support UK in maintaining a leading role in the field of energy storage - one of the pillar technologies identified by the UK's government industrial strategy iii) it will test additive manufacturing in the novel context of thermal energy storage; therefore it will offer the opportunity of a new market sector for additive manufacturing products.

Oesophageal cancer has the fastest rate of increase of any cancer in the developed world and a poor prognosis with low survival after five years. Early identification of changes in oesophageal tissue leads to improved prognosis, but current techniques rely on traditional endoscopy and biopsy, which are invasive and exhibit poor sampling, and are only capable of identify issues that have already manifested through changes in the cellular structure. Recent developments in photonic-based technologies mean that it is now feasible to develop a medical diagnostic that is capable of identifying pre-cancerous (Barrett's syndrome), cancerous and non-cancerous tissues, by analysing the spectral properties of laser light inelastically scattered from tissue (Raman spectroscopy). By performing Raman spectroscopy at the end of a thin and flexible fibre-optic, that is used to precisely guide light into and out from the region of interest, it will be possible to test in-vivo whether oesophageal tissue is malignant or normal. This technique may also be able to pick up abnormalities that would not be picked up during histopathology, crucial information that could enable early diagnosis and mean that unnecessary invasive surgical procedures could be avoided. Such a technology would also find applications in the endoscopic treatment of Barrett's oesophagus and oesophageal cancer, enabling the clinician to assess the margins of the relevant tissue regions before and during resection. There is, however, a significant manufacturing issue that stands in the way of fully developing these new and exciting photonic-based clinical tools; in order to control the properties of the light leaving and entering the distal (in-vivo) end of the fibre-optic, it is necessary to use a distal-end-optical-system (DOS) of some form. This DOS can be as simple as a single lens, or a more complicated construction, requiring mirrors, spectral filters and lenses, as is the case in the optical-biopsy Raman-based instrument. Currently, manufacturing such DOS devices requires discrete micro-optic components to be aligned and bonded together. These techniques are labour intensive, time-consuming and expensive. In short, current DOS fabrication techniques are non-optimal and are not suitable to commercial manufacturing; a new and more flexible manufacturing technique is required. During this STFC-CLASP project, we will develop new DOS manufacturing processes using ultrafast laser based techniques. These processes use focused ultrashort laser pulses, each only a few hundred femtoseconds long, to locally and precisely modify the structure of a substrate material in three-dimensions. The laser-induced modification manifests itself in a variety of ways, examples of which include changes to the chemical etch-rate and/or refractive index of the modified material. Using these manifestations, it is possible to directly write optical components, such as diffraction gratings, into the substrate material, and by using a post-irradiation chemical-etch step we can sculpt precision micro-optics. The fact that "ultrafast laser inscription" enables micro-optic components, such as lenses, mirrors and optical waveguides to be combined onto a single substrate, using a single manufacturing process, makes it the ideal route to commercially manufacture precision DOS technologies.