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Details of Grant 

EPSRC Reference: EP/P006566/1
Title: MAPP: EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes
Principal Investigator: Todd, Professor I
Other Investigators:
Panoutsos, Professor G MUMTAZ, Dr K Rainforth, Professor WM
Grant, Professor P Mullis, Professor AM Kadirkamanathan, Professor V
Bayly, Professor A Hassanpour, Dr A Hughes, Dr J
Giuliani, Professor F Saiz Gutierrez, Professor E Preuss, Professor M
withers, Professor P Prangnell, Professor P Lee, Professor P
Vandeperre, Professor LJ Jackson, Professor M Majewski, Dr CE
Researcher Co-Investigators:
Project Partners:
Centre for Process Innovation CPI (UK) Eastman Chemical Ltd (inc) Element Six
Freemantechnology GKN Aerospace (Melrose) Johnson Matthey
LPW Technology Ltd (UK) MAHER Limited Messier-Dowty Ltd
Metalysis Ltd Morgan Advanced Materials plc (UK) National Composites Centre
Nuclear AMRC Phoenix Renishaw
Rolls-Royce Plc (UK) Seco Tools The Manufacturing Technology Centre Ltd
The Weir Group plc University of Sheffield University of Strathclyde
University of Warwick Xaar Plc Zeiss (Carl Zeiss AG)
Department: Materials Science and Engineering
Organisation: University of Sheffield
Scheme: Standard Research
Starts: 01 October 2016 Ends: 30 June 2024 Value (£): 10,724,131
EPSRC Research Topic Classifications:
Manufacturing Machine & Plant Materials Processing
Particle Technology
EPSRC Industrial Sector Classifications:
Aerospace, Defence and Marine Manufacturing
Chemicals Energy
Related Grants:
Panel History:
Panel DatePanel NameOutcome
14 Jul 2016 Manufacturing Hubs 2016 Interviews Announced
13 Jun 2016 Manufacturing Hubs 2016 Full Sift Announced
Summary on Grant Application Form
Manufacture Using Advanced Powder Processes - MAPP

Conventional materials shaping and processing are hugely wasteful and energy intensive. Even with well-structured materials circulation strategies in place to recondition and recycle process scrap, the energy use, CO2 emitted and financial costs associated are ever more prohibitive and unacceptable. We can no longer accept the traditional paradigm of manufacturing where excess energy use and high levels of recycling / down cycling of expensive and resource intensive materials are viewed as inevitable and the norm and must move to a situation where 100% of the starting material is incorporated into engineering products with high confidence in the final critical properties.

MAPP's vision is to deliver on the promise of powder-based manufacturing processes to provide low energy, low cost, and low waste high value manufacturing route and products to secure UK manufacturing productivity and growth. MAPP will deliver on the promise of advanced powder processing technologies through creation of new, connected, intelligent, cyber-physical manufacturing environments to achieve 'right first time' product manufacture. Achieving our vision and realising the potential of these technologies will enable us to meet our societal goals of reducing energy consumption, materials use, and CO2 emissions, and our economic goals of increasing productivity, rebalancing the UK's economy, and driving economic growth and wealth creation.

We have developed a clear strategy with a collaborative and interdisciplinary research and innovation programme that focuses our collective efforts to deliver new understanding, actions and outcomes across the following themes:

1) Particulate science and innovation. Powders will become active and designed rather than passive elements in their processing. Control of surface state, surface chemistry, structure, bulk chemistry, morphologies and size will result in particles designed for process efficiency / reliability and product performance. Surface control will enable us to protect particles out of process and activate them within. Understanding the influence between particle attributes and processing will widen the limited palette of materials for both current and future manufacturing platforms.

2) Integrated process monitoring, modelling and control technologies. New approaches to powder processing will allow us to handle the inherent variability of particulates and their stochastic behaviours. Insights from advanced in-situ characterisation will enable the development of new monitoring technologies that assure quality, and coupled to modelling approaches allow optimisation and control. Data streaming and processing for adaptive and predictive real-time control will be integral in future manufacturing platforms increasing productivity and confidence.

3) Sustainable and future manufacturing technologies. Our approach will deliver certainty and integrity with final products at net or near net shape with reduced scrap, lower energy use, and lower CO2 emissions. Recoupling the materials science with the manufacturing science will allow us to realise the potential of current technologies and develop new home-grown manufacturing processes, to secure the prosperity of UK industry.

MAPP's focused and collaborative research agenda covers emerging powder based manufacturing technologies: spark plasma sintering (SPS), freeze casting, inkjet printing, layer-by-layer manufacture, hot isostatic pressing (HIP), and laser, electron beam, and indirect additive manufacturing (AM). MAPP covers a wide range of engineering materials where powder processing has the clear potential to drive disruptive growth - including advanced ceramics, polymers, metals, with our initial applications in aerospace and energy sectors - but where common problems must be addressed.

Key Findings
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Organisation Website: http://www.shef.ac.uk