Techniques such as abrasive water jet machining (AWJ), pulsed laser ablation (PLA) and ion beam machining (IBM) are all methods of energy beam processing, by which energy is transferred to a surface and material is removed; this group of technologies can be employed to generate freeforms surfaces by controlled-depth machining. Although the way in which the energy is transferred in each of these methods is very different (AWJ: a high speed mixture of air, grit and water mechanically erodes the surface; PLA: laser pulses vaporize the surface; IBM: high speed charged particles erode the surface), they can be dealt under a unified mathematical framework whereby the rate of erosion of the surface is described by a partial differential equation. This equation relates the footprint of an energy beam (its instantaneous rate of removal, which may be a function of the geometry of the eroding surface, its distance from the source of the beam as well as position within the beam and beam orientation) to the evolution of the surface. The Investigators in this proposal have had significant success in using this mathematical framework to determine the final, machined surface for a given beam footprint and dynamic beam path; this is the forward problem. However, the problem that is of industrial interest is the inverse problem; given a required final surface, how should the beam be moved in order to accurately machine it? Currently, in both academic research and industry, this problem is solved by trial and error (craftmanship). The aim of this project is to develop methods for solving the inverse problem algorithmically, so that end users of this group of technologies (i.e. energy beam controlled-depth machining) can input their required surface into a software package and automatically generate a beam path. We will do this by tackling a series of increasingly realistic mathematical problems which can be related to real energy beam processes, backed up by an experimental programme against which our models can be verified.

Precision laser processing has much potential for advanced manufacturing. Features can be machined at a fraction of a micrometre in size in a wide range of materials. The use of ultrashort laser pulses (with duration less than a picosecond) is important since all of the laser pulse energy is delivered to the focus in a timescale shorter than that for thermal diffusion. Therefore, all the material machining is done before any energy can escape as heat, which underpins the high resolution of the technique. Ultrashort laser pulses provide other unique opportunities, since they can be used for three-dimensional fabrication inside transparent materials, with a range of applications for smart technology. Such precision laser processing is already applied on an industrial scale, with examples such as accurate cutting of glass for smartphones or multi-dimensional data storage. With a constant drive for miniaturisation and enhanced functionality, the sector is destined to blossom over the next decade. The ability to fabricate features at the sub-micrometre scale presents many opportunities for advanced technology. However, accurate positioning of such small features in three dimensions inside centimetre scale workpieces creates a serious challenge. Machine vision uses imaging solutions integrated inside the manufacturing system to provide feedback for the laser process to ensure that the device is machined as designed. However, existing hardware and software systems cannot meet the challenging demands of such high precision laser processing. In this project, we develop new hardware and software solutions that will enable rapid three-dimensional imaging at high resolution. We also introduce new systems that can provide a macroscopic view of the entire device being processed. Additionally we establish innovative forms of optical feedback that can be applied to closely monitor the laser manufacturing process. All of this information is merged together inside a cohesive software framework, that can provide quick data transfer of important information to the laser manufacturing system. This enables quicker, more accurate laser processing of smaller features in demanding applications, to enable industrial scale manufacturing of advanced technology.

Metal thin films are used in a wide variety of technologies, such as solar cells and printed circuit boards for electronics. Inkjet printing has emerged as a practical and low-cost route for manufacturing electrical contacts in these applications. However existing manufacturing technologies use inks that often require a final heat treatment to consolidate or 'sinter' the film. If this last step can be eliminated, by depositing fully dense films, then the inkjet manufacturing process could be applied to temperature sensitive substrates like plastics or vulnerable semiconductor materials. The purpose of this project is to develop 'sinter-free' inkjet manufacturing processes, by taking ink precursors developed for other thin film processes, and exploiting them to use the significant benefits of inkjet process technology e.g. the direct writing of interconnects or wires. If successful, the project will represent a step-change in the manufacturing methods for this type of film.

Currently, special fibres are a crucial enabling technology that communicates worldwide, navigates airliners, monitors oil wells, cuts steel, and shoots down missiles (and even mosquitoes!). New classes of special optical fibres have demonstrated the potential to extend the impact of optical fibres well beyond the telecommunications arena, in areas as diverse as defence, industrial processing, marine engineering, biomedicine, DNA processing and astronomy. They are making an impact and commercial inroads in fields such as industrial sensing, bio-medical laser delivery systems, military gyro sensors, as well as automotive lighting and control - to name just a few - and span applications as diverse as oil well downhole pressure sensors to intra-aortic catheters, to high power lasers that can cut and weld steel. Optical fibres and fibre-related products not only penetrate existing markets but also, more significantly, they expand the application space into areas that are impossible by conventional technologies. To fulfil this potential and further revolutionise manufacturing, there is a strong need to continue innovating and manufacturing market-worthy fibres, in order to sustain the growth in the fast expanding fibre-based manufacturing sectors.From its inception in the 1960s, the UK has played a major role in shaping the optical fibre industry, and the highly regarded Optoelectronics Research Centre (ORC) at the University of Southampton is at the forefront. Our vision is to build upon the rich expertise and extensive facilities that are already in place to create a world-class, industry-led Centre for advanced manufacturing processes for new photonic components and materials that will fuel the growth of UK companies, enabling them to expand their product portfolio, enhance competitiveness and increase their market penetration and overall share. We will liaise closely with UK and other European Research Centres to advance further the fibre and related material technology, as well as increase the application space. The Centre is expected to play a key role in job and wealth creation in the expanding and highly competitive advanced technology and manufacturing sector. The UK industrial sector accounts for a production volume in photonics of EUR 5.2 billion, which corresponds to 12% of the European volume, and 2.3% of the world market. Particularly notable about the photonics industrial sector is that it comprises a majority of SMEs, who typically do not have the economies of scale nor the financial resources to invest heavily in infrastructure on their own. Use of the Innovative Manufacturing funding mechanism, complemented by industrial user-provided direct and in-kind contributions of ~4M (similar in amount to that sought from EPSRC for the establishment of this IMRC) , will supply the seed funding and focus needed to research and develop the next generation fibre material and technology platforms, which in turn will fuel the growth in photonics related manufacturing. The establishment of such a manufacturing research centre, working closely with existing key high-tech photonic UK companies as well as emerging companies and new start-ups, will make a substantive difference to their ability to develop and gain larger penetration in their respective markets. The IMRC strategy will follow multiple strands taking a number of initiatives to continuously expand and strengthen the initial research portfolio by moving it further up in the innovation and value-added spectrum. During its lifetime, the IMRC will make concerted efforts to further increase the user number and level of engagement.

The project aims to create a new Hub that will act as a national gateway for Advanced Metrology, engaging with UK industry to co-create and co-deliver frontier and innovative research and technologies, and with policy makers and scientific leaders, to drive future UK manufacturing excellence with a clear emphasis on sustainability. The Hub will have environmental and economic sustainability embedded throughout its programme, both in terms of prioritising industry challenges that the research will address, and within the operational delivery. One of the largest challenges in improving sustainability in manufacturing is the availability of the actionable information that is essential to both improve existing processes to reduce waste, and to enable new processes and methods that significantly enhance resource efficiency through reduced energy usage, material reuse and recycling, and reduced transportation (as a result of supply-chain efficiency). By delivering a future where pervasive metrology systems sense, monitor and control manufacturing systems to self-optimise, we will realise the connected and autonomous systems critical for achieving net zero. Delivering these advances requires the development of manufacturing systems that cannot be realised without a new integrated paradigm in metrology, embracing ultra-fast and compact sensors, distributed artificial intelligence (AI) technologies, and autonomous prognostics control systems far beyond the current state-of-the-art. Hence, the Hub's research programme will be structured around three underpinning research themes to address three Key Research Objectives: Create and apply new sensor technologies incorporating nanophotonics/quantum sensing principles combined with photonic edge computing to realise high-precision ultra-fast, ultra-compact, and low-cost sensors/instruments within smart manufacturing processes and systems. Create and apply new resilient and interpretable metrology aimed at capturing actionable information for sustainable manufacturing. Unify whole system autonomous control for sustainability in manufacturing machinery systems, which optimises process, energy use and resource efficiency in complex systems at the design state and through life. When combined, these objectives will deliver universal 'measurement/analysis/control' solutions for early adoption to address sustainable manufacturing challenges. Five priority areas have been identified to demonstrate new metrology technologies and methods; sustainable and connected machinery, zero carbon transport, clean energy systems, semiconductors, and manufacturing reuse. The programme will develop and demonstrate new metrology technologies and methods with clear applications in these sectors. This will be achieved working closely with metrology equipment/software/service providers, manufacturing systems providers, and with manufacturing end-users, supported closely by partners across the UK Catapult network and national and international standardisation bodies. The Hub comprises a substantial consortium, led by the Centre for Precision Technologies at Huddersfield. Initial research spokes will be based at Heriot-Watt, Oxford, Queens (Belfast) and Southampton universities, with Innovation Spokes at The Manufacturing Technologies Centre (MTC) and the Advanced Manufacturing Research Centre (AMRC), and a hybrid Research/Innovation Spoke at the National Physical Laboratory (NPL). Over 25 industrial partners were involved in co-creating the Hub and will be working with the research team to support, delivery and accelerate commercialisation of research outcomes via sponsored research projects, knowledge exchange, technology transfer (IP licensing and spin-out), and training/skills development.