High Value Manufacturing Catapult

An overview
 The HVM Catapult is the catalyst
for the future growth and success
of manufacturing in the UK.

We help accelerate new

concepts to commercial reality
and thereby create a sustainable
high value manufacturing future
for this country.

Our ultimate aim is to significantly grow

the contribution of the manufacturing
sector to the UK economy.
Bridging the gap to
commercial success

The UK has a track record of generating good

ideas and innovations. Too often however, we
do not turn such inventions into commercial
products in the UK, thus allowing others to
make the economic gain from our inventions.

The journey of a good idea into a saleable By working with HVM Catapult, our customers
product is illustrated below, using the reduce that risk significantly because they
Technology Readiness Scale. have access to the facilities and the expertise
needed, and can defer the main investment
Level 1-3 is the stage from idea to functioning decision until it’s been established that the
prototype, often taking place in a research innovation can be scaled up and is realisable
institution, university or laboratory. on a commercial scale.

Level 4-6 is the translational space – moving At that stage, they enter level 7-9, where private
the prototype to proof of commercial viability. investment turns the proven concept into
This is where HVM Catapult operates. industrial scale manufacturing activity.

The translational activity is the risky, expensive

stage, often involving significant investments in
equipment and people, without any guarantee of
success. It is estimated that 80% of innovations
fail in this so-called Valley of Death.

Experimental Technology
Applied R&D
research implementation

TRL 1 TRL 2 TRL 3 TRL 4 TRL 5 TRL 6 TRL 7 TRL 8 TRL 9

Research Councils
Universities Catapult focus Private Sector Funds
Who we work with

Size Innovation Value

We work with companies of all sizes, We work with companies seeking We work with companies operating
from small start-ups to large OEMs. to investigate innovative technologies in high value manufacturing ie:
or scale up new products and manufacturing that requires a high
processes to prove they have level of R&D and has the potential to
achieved manufacturing readiness. yield high returns for the UK.
Our offer

We have capability We provide companies

which spans basic raw with access to world-
materials through to class facilities and
high integrity product skills to scale-up
assembly processes. and prove-out high
value manufacturing
processes.

We develop a network We unite industry,

of leading suppliers who government and
contribute to key UK research in a shared
industry supply chains. goal to make the UK
an attractive place to
invest in manufacturing.
7centres
Through our 7 centres we have capabilities
and competences which span basic raw
materials through to high integrity product
assembly processes.

Shaping the future, forging partnerships

> High integrity forging and thermal Advanced Forming Research Centre
processing University of Strathclyde
> Materials evolution, component 85 Inchinnan Drive
resilience and residual stress Inchinnan
Focused on developing metal forming and > Near net shape design and make Renfrew PA4 9LJ
forging technologies to support the design > Sheet processing technology
and advanced manufacture of products. > Digitalisation, technology planning T: +44 (0) 141 534 5200
of process and supply chains F: +44 (0) 141 562 3387
E: info@afrc.org.uk
www.afrc.org.uk
At the cutting edge of collaborative research

> Additive > Manufacturing Advanced Manufacturing Research Centre –

Manufacturing Informatics AMRC with Boeing
> Automation > Machining The University of Sheffield
> Castings > Manufacturing Advanced Manufacturing Park
World-class centre for collaborative research > Composite Intelligence Wallis Way, Catcliffe
focused on advanced machining and Manufacturing > Medical Rotherham S60 5TZ
materials for aerospace and other high value > Design and > Metrology
manufacturing sectors. Prototyping > Microscopy T: +44 (0) 114 222 1747
> Digitally Assisted > Robotics E: enquiries@amrc.co.uk
assembly > Structural Testing  @theAMRC
> Virtual Reality www.amrc.co.uk

From innovation to commercialisation

> Printable Electronics Centre for Process Innovation

> Formulation Wilton Centre
> Industrial Biotechnology Wilton
> Biopharmaceuticals Redcar
Helping companies to develop, prove and > Graphene TS10 4RF
commercialise the next generation of products,
processes and services. Enabling ideas, T: +44 (0) 1642 455 340
research and knowledge to be translated into E: info@uk-cpi.com
commercial business propositions by providing  @ukCPI
the facilities and technical expertise to help www.uk-cpi.com
companies overcome their innovation challenges.
Challenging the boundaries of manufacturing

> Additive Manufacturing Manufacturing Technology Centre

> High Integrity Fabrication Ansty Park
> Non Conventional Machining Coventry
> Advanced Tooling and Fixturing CV7 9JU
Inspiring great British manufacturing, > Electronics Manufacturing
on the global stage. > Robotics and Autonomous Systems T: +44 (0) 24 7670 1600
> Special Purpose Machines E: reception@the-mtc.org
> Manufacturing Simulation  @the_MTC_org
> Manufacturing Informatics www.the-mtc.org
> Metrology and NDT

Innovation Accelerated. People Developed. Solutions Delivered

> Design, analysis and simulation of The National Composites Centre

advanced composites applications Feynman Way Central
> Product and process development and Bristol & Bath Science Park
Providing solutions for the design, manufacture optimisation Emersons Green
and application of thermoplastic & thermoset > Materials through intermediates and Bristol
composites and multi-materials, in an preforming to end product BS16 7FS
open‑access centre, focusing on research, > Extensive range of deposition and curing
technology development, transferring technologies T: +44 (0) 117 370 7600
knowledge and people development: > Application of digital technology to E: info@nccuk.com
composites manufacturing  @NCCUKinfo
> Prototyping and validation @NCCUKComms
> Manufacturing, inspection and testing www.nccuk.com
> Collaborative and confidential working
environments
Helping UK manufacturers win work in civil nuclear

> Intelligent machining Nuclear AMRC

> Modularisation University of Sheffield
> Laser welding & cladding Advanced Manufacturing Park
> Mechanised arc welding & cladding Brunel Way
Working with UK companies of all sizes to > Ultra thick section joining Catcliffe
enhance their manufacturing capabilities for > Large-volume metrology Rotherham S60 5WG
nuclear and other innovative energy sectors. > Metal powder manufacturing
> Bulk additive manufacturing T: +44 (0) 114 222 9900
> Surface integrity E: enquiries@namrc.co.uk
> Visualisation  @NuclearAMRC
www.namrc.co.uk

Addressing the global challenge of low carbon mobility

> Connected and autonomous systems WMG

> Efficient use of materials International Digital Laboratory
> Energy innovation University of Warwick
One of the world’s leading research and > Advanced propulsion systems Coventry
education groups. Working with businesses of CV4 7AL
all sizes to overcome the challenges associated
with low carbon mobility. T: +44 (0) 24 7615 1667
E: wmgbusiness@warwick.ac.uk
 @WMGBusiness
wmg.warwick.ac.uk
Key technology capabilities

Through our seven centres we offer technology

innovation and scale-up capabilities across
the spectrum of process and discrete
manufacturing industries.

These technologies are available:

1
At an industrial scale on an open-access basis so companies
of all sizes can develop their processes, products and services,
on state of the art equipment.

2
To allow companies to test alternative approaches to innovation Advanced Assembly
so they can lower risk without incurring significant capital costs.

Assembly is the general term for applications

that assemble and inspect the fundamental
parts to form a final product or sub‑component.
Industry is increasingly seeking to automate
3 complex manual assembly tasks in order to
So academia and university spin-outs can scale-up their
improve manufacturing flexibility, speed and
research in a way that prepares them for commercial markets.
quality, while also reducing costs.

4
Along with extensive experience available through the highly
skilled technology development teams in the centres.

Automation
Automation is the use of various control
systems for operating equipment such as
machinery, processes in factories, and other
applications with minimal or reduced human
intervention. Some processes have been
completely automated.
Biologics Biotechnology Casting
Biologics are preparations, such as a drug, Biotechnology uses microorganisms, such as Casting involves liquid material being poured
a vaccine, or an antitoxin, that are synthesized bacteria or yeasts, or biological substances, into a hollow mould, and being left to solidify.
from living organisms or their products such as enzymes, to perform specific industrial Casting innovation through computer
and used as a diagnostic, preventive, or or manufacturing processes. Biorefining is process modelling of molten metal flow and
therapeutic agent. the sustainable processing of biomass into a solidification, design for casting and new
spectrum of bio-based products and bioenergy casting processes and materials, improves
(biofuels, power and/or heat). product performance and reduces cost.

Composites Design
Composite materials are materials made Design for manufacture is a term used to
from two or more constituent materials with describe the process of designing products/
significantly different physical or chemical parts/components in a way that optimises
properties, that when combined, produce a all the manufacturing functions (fabrication,
material with characteristics different from assembly, test) as well as ensuring that design
the individual components. supports the optimisation of cost, quality and
regulatory compliance.
Digital Manufacturing Electronics Flexible Manufacturing
Advanced manufacturing is a highly knowledge Electronics deals with electrical circuits that A method for producing goods that is readily
intensive sector where advances in IT involve active electrical components such as adaptable to changes in the product being
systems have a huge role to play in improving vacuum tubes, transistors, diodes and integrated manufactured, in which machines are able
manufacturing intelligence; capturing, sharing circuits, and associated passive electrical to manufacture parts and with the ability to
and managing big data; supporting collaboration; components and interconnection technologies. handle varying levels of production.
increasing efficiency; speeding up innovation; and
enabling new business models and technologies.

Formulations High Temperature

Processing
Formulations refer to the putting together of
components in appropriate relationships or Forming of metallic components by use
structures, according to a formula. Formulations of carefully controlled combinations of
are commercially produced for drugs, coatings, temperature and pressure to effect
dyes, alloys, cleaning agents, foods, lubricants, viscoelastic flow and/or plastic deformation.
fuels, and many others.
Joining Machining Manufacturing
with Polymers
Joining technology is fundamental to engineering Machining is any of various processes in
and manufacturing. Without the ability to make which a piece of raw material is cut into a Polymeric materials are created via
strong and durable connections between desired final shape and size by a controlled polymerisation of many small molecules.
materials it would not be possible to produce material-removal process. Their consequently large molecular mass
the many different items upon which industry relative to small molecule compounds
rely, and we all rely on in our everyday lives. produces unique physical properties, including
toughness, viscoelasticity, and a tendency to
form glasses and semicrystalline structures
rather than crystals.

Materials Characterisation Metal Forming and Forging

Characterisation and testing of materials refers Forging is a manufacturing process involving
to the broad and general process by which a the shaping of metal using localized
material’s structure and properties are probed, compressive forces. Forging is often classified
measured and tested. according to the temperature at which it is
performed: “cold”, “warm”, or “hot” forging.
Metrology Modelling and Simulation Netshape and Additive
Manufacturing
Metrology (the science of measurement) Modelling and simulation is getting information
provides critical quality assurance for about how something will behave without Additive manufacturing (AM) (or 3D printing)
manufacturing processes. actually testing it in real life. Models, including uses primarily additive processes, in which
emulators, prototypes and simulators, either successive layers of material are laid down
statically or over time, are used to develop data under computer control. This results in objects
to inform managerial or technical decisions. that can be of almost any shape or geometry,
and are produced from a 3D model or other
relevant data source, with little or no waste.

Powder Technology Power and Energy Storage

Many of the emerging production methods that Environmental legislation is creating a
produce net shape components (components significant demand for electrochemical
close to final geometry without the need for storage solutions for both static (grid
extensive machining) begin with powdered balancing and storage of renewable energy)
metals. The powder metallurgy industry has and mobile application (low carbon vehicles).
witnessed a steady expansion since the 1980s
and continues to reinvent itself, introducing
new materials, products and services.
Printable Electronics Resource Efficient and Surface Engineering
Sustainable Manufacturing
Printable electronics refers to the methods Surface engineering refers to a wide range of
used to create electrical devices on various The efficient use of resources in technologies designed to modify the surface
substrates including thin film, textiles and paper. manufacturing processes coupled with properties of metallic and non-metallic
Development of printable electronics technology low carbon and low energy manufacturing components for decorative and/or functional
provides benefits for end-users across sectors processes is a major target across the purposes. Examples include improving
and has the potential to enable products to whole of the manufacturing industry. corrosion and wear resistance to extend
be lower cost, lighter in weight, and to provide component life; making items more visually
more integrated functionality and lower energy attractive; and giving special properties such as
consumption both in manufacture and use. lubricity enhancement, non-stick surfaces, etc.

Tooling and Fixtures Visualisation and

Virtual Reality
Tooling refers to working or specialist
manufacturing aids which are usually limited Virtual reality refers to a set of techniques in
in use to a specific production line or the which one interacts with a synthetic (“virtual”)
performance of a specific contract or job. environment that exists solely in the computer.
Fixtures are work holdings, used to securely A variant of virtual reality is often called
position, hold and support the work to “Visualisation”. This involves presentation of
maintain conformity. 3D structures (such as anatomy or molecular
structure) in ways that maximize learning.
Achievements and impact

The HVM Catapult receives core funding from government through In 2015, WECD undertook an economic impact evaluation of
Innovate UK. This core funding must be matched with competitively won HVM Catapult. Key findings from the study, which can be downloaded
collaborative R&D funding, and with industry income. This so-called 1/3 from hvm.catapult.org.uk, are below:

£15 £1
1/3 1/3 model is crucial to the success of the Catapult. To date, after
merely four years of operation, the demand for our services and the net benefits
income we receive from business has far exceeded the 33% target. to the UK core public
economy funding
from every received

Source: WECD Economic Impact Evaluation study

36% 33%

31%

 ore public
C  ompetitively
C  ommercial
C
funding won CR&D income

Total value of our assets Number of employees Size of order book

£617m 2,114 £205m

Up 10% from Of which £137m is
2015-16 collaborative R&D

Number of private Investment in large

sector projects Private sector clients capital projects:

1,730 3,387 £52m

Over 40% of whom
(1,383) are SMEs
Source: HVM Catapult Annual Review 2016-17
Success stories

Flexible inspection Increasing the scale Needle free

automation cell shortens and speed of ‘breathalyser’ for daily
cycle-time commercialisation diabetes testing

AFRC and partners, including KUKA Robotics With the support of the AMRC, Yorkshire- Applied Nanodetectors Ltd worked with CPI
UK, produced a full-size, flexible inspection based SME Technicut developed a cutting on developing a simple breathalyser test
automation cell for Spirit Aerosystems to help tool that speeds up the cutting of tough alloys for daily monitoring of glucose levels in
meet the growing demand for highly accurate such as titanium, with machine time on an diabetics. A non-invasive handheld breath
measurements at reduced timescales. The engine component reduced from two minutes test device has the potential to replace
project has delivered significantly reduced cycle 52 seconds to five seconds. The AMRC then the ‘prick test’ methods used today
time in the complex geometry inspection of the brought in tool-holder specialist Nikken and and would significantly improve patient
large‑wing systems that Spirit manufacture. they collaboratively developed a system which monitoring and self-management.
maximises the capacity of the cutting tool
For a 6m² part, overall inspection time has and reduced cycle time for one part from The collaboration is part of an Innovate UK
been reduced from 2.4 hours to around 50 36 hours to 11 hours, with only six milling project – ‘Plasense’ – which developed a
minutes; a reduction of 65%. This step change tools doing the work previously done by more low-cost and scalable method for printing
will underpin the productivity of Spirit as than 30 tools. sensors onto flexible plastic substrates.
it responds to industry demand, which is Further work will look at upscaling the
expected to double to 100 wing sets per month. As a result, Japanese-based Nikken built a sensor and integrating it into a point‑of‑care
new European R&D centre in Sheffield and the diagnostic device. The project is a key
tool is now manufactured in the UK and has breakthrough for the monitoring of glycemic
since been adopted by machining workshops levels and the technology will revolutionise

Largest ever 3D printed around the world. The Technicut tool was the way in which we monitor glucose.
also one of the key innovations adopted by
aero engine component the combined team of AMRC and Rolls-Royce
as they sought to reduce the time involved
in machining Trent 900 fan discs, which had
The MTC worked with Rolls-Royce on
become uneconomic to manufacture in the
the additive manufacture of a flight test
UK. As a result, machine time was halved and Working with CPI has helped
front-bearing housing, resulting in a 30%
productivity on engine discs doubled. to accelerate the sensor
improvement in lead time for first part
to stores for the engine development development cycle and
programme. Working in conjunction with utilise plastic electronics
Rolls-Royce and Arcam, the MTC developed
technologies to obtain
processes from powder inspection and
characterisation to component manufacture the most cost-effective
and post-process non-destructive manufacturing solution.
testing of the additive layer manufactured
components. As a result of this work, Dr Victor Higgs, Managing Director,
hundreds of aerospace quality components Applied Nanodetectors Ltd
were manufactured under full Rolls‑Royce
control, with tens of thousands of equipment
run‑hours allowing for extensive data capture.

This resulted in the electron beam

additive-manufactured components being
incorporated into ground and flying test-bed
XWB-97 engines.
Success stories

Helping UK Dymag reinvents Remote Laser Welding

manufacturing companies the wheel Navigator: outstanding
compete in nuclear research with industrial
relevance

Over 600 companies have undertaken the Pioneering Wiltshire-based wheel The Remote Laser Welding (RLW) Navigator
Nuclear AMRC’s Fit for Nuclear (F4N) supplier manufacturer Dymag worked with the NCC to was a 3½ year collaborative programme led
development initiative (a unique service support their composites technology. Their by WMG with 12 industrial and academic
to help UK manufacturing companies get latest wheels are made in one-third of the partners including STADCO, Jaguar Land Rover
ready to bid for work in the civil nuclear original cycle‑time and at a reduced cost. and EnginSoft (a UK SME). The programme
supply chain), with 100 having completed the The improvement in productivity and unit developed software solutions to enable the
programme and half already experiencing cost supports Dymag’s aspiration to increase implementation of RLW technology, effectively
significant business benefits. The larger OEM market reach. The wheels are typically taking it from new concept to production.
scale Civil Nuclear Sharing in Growth (CNSIG) 40% lighter than standard cast aluminium
programme (an intensive business support wheels and 25% lighter than equivalent forged The main barrier for adoption of RLW has
programme to help manufacturers compete aluminium wheels, when tested to the same been the lack of methodologies for precise
for work in the civil nuclear industry) has seen OEM standards. The team applied design and effective planning and simulation of
10 key nuclear suppliers undertake a four-year and simulation tools to produce a solution its application, leading to time-consuming
programme led by the Nuclear AMRC. After with light weight composites material as an (and expensive) trial-and-error procedures.
three years, the companies have won £410m alternative to heavier metal wheels. The new solution developed a range of new
of new contracts, created or sustained 4,900 capabilities and the results from the RLW
jobs and committed £45m of additional Application of manufacturing process Navigator programme led to the first ever
private sector funding. knowledge at the product design stage has fully digitally developed RLW process.
ensured improved repeatability and efficiency.
Through the CNSIG programme, the Nuclear The NCC has provided high standards of The project has enabled the adoption of
AMRC is developing new methods of product and process prototype development, RLW leading to greatly improved productivity
manufacture to support the suppliers of the test and analysis support, and iteration which (up to 5 times faster and with 60% less
current 3m³ Intermediate Level Waste (ILW) has led to further work with Dymag to help floor space), reduced costs, enhanced
containers to Sellafield Ltd. This programme with refining design and increasing the rate of flexibility and reduced weight through
includes developing new machining methods manufacturing output. RLW optimised design.
aimed at increasing the security of supply
and cost effectiveness for Sellafield Ltd to
support their high priority decommissioning
programmes over the next decade or so. With
an eventual requirement of over 100,000 ILW
containers over the next 120 years, Sellafield We worked very closely with the NCC in developing our
has also engaged the Nuclear AMRC in a
longer-term programme to develop alternative
new and patented Boxstrom carbon rim. We are absolutely
designs of waste containers with the objective delighted at the way the market (OEM’s and aftermarket)
of reducing the unit cost by 50%. is responding to the Boxstrom. Thanks to our design
and development work in partnership with the NCC the
Boxstrom offers a wide range of performance features
that make it our lightest, stiffest and strongest carbon
composite wheel yet.
Chris Shelley, CEO, Dymag
HVM Catapult
Regus Building
Blythe Valley Business Park
Shirley
B90 8AG

hvm.catapult.org.uk
+44 (0)1564 711540
 @HVM_Catapult

AFRC

CPI

AMRC
Nuclear AMRC
MTC
WMG

NCC
V2 08.2017