AMRC Design & Prototyping Group Capability Directory

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AMRC Design & Prototyping GroupCapability directory

The AMRC Design & Prototyping Group providesengineering design and prototyping expertiseto help UK manufacturers develop innovative,high-value products.The Group was created in 2012 because a severeshortage of exceptional engineering designers had lefttop-tier manufacturers and suppliers struggling to find thedesign expertise they needed to bring new products andcomponents to market.Problems were particularly acute in high-valuemanufacturing sectors like aerospace, energy,motorsport and medical technology, where designersneed to work closely with R&D, prototyping and testingcentres to perfect their designs through a series ofintense product development cycles.In response, the AMRC created a manufacturing designresource capability far beyond anything previouslyavailable in the UK by integrating a world-class designteam with the manufacturing and research expertise ofits established groups.e: enquiries@amrc.co.ukt: 44 (0)114 222 1747The Group’s workshop in the AMRC Design Prototypingand Testing Centre has a range of advanced machinetools and additive manufacturing facilities. Machineshave been carefully selected to supplement the AMRC’sexisting technology, giving companies access toequipment which can produce parts as delicate as theworkings of a watch or as geometrically complex as abespoke replacement knee joint.We can handle high-performance milling and grindingof ceramics, superalloys and other medical andaerospace grade materials, as well as 3D printing ina range of materials.For more information, contact:Derek Boaler – AMRC head of designd.boaler@amrc.co.ukw: amrc.co.uk2

AMRC Design & Prototyping GroupCapabilities overviewThe AMRC Design & Prototyping Group can bring a wide range of capabilitiesand expertise to our industrial partners.Technical capabilitiesOur technology teams develop the techniques and underpinning science thatcan deliver significant improvements in engineering performance, including:Stage Gate Product Development Click page to jump page 4 page 5 page 6 page 7 page 8 page 9 page 10Design ThinkingDesign for Additive ManufacturingAnalysisMechanical DesignElectrical DesignMedical AMRCTo put this expertise into practice, we work with an array of state-of-the-arttechnologies located in the Design Prototyping and Testing Centre.We have a wide variety of available technologies, many of which areoptimised for specific prototyping applications. Our resources are availablefor collaborative research and development projects, giving companies thecapability to develop innovative and optimised engineering solutions.The following pages introduce the capabilities, core research areas andresources of the design and prototyping teams.e: enquiries@amrc.co.ukt: 44 (0)114 222 1747w: amrc.co.uk3

DPG technical capabilitiesStage Gate Product DevelopmentThe Design & Prototyping Group has created a five stage design anddevelopment process, moving from Initiation and Concept Generation,through to Detailed Design, Validation and Lessons Learnt.The brief is defined and set during Initiation, initial ideasare explored during Concept Generation, after which thechosen design is developed in the Detailed Design stage.Prototyping and testing takes place at the Validation Stageand the final, critical stage, Lessons Learnt, ensures ourfuture projects benefit from the outcomes of past projects.Each stage of the process is supported and monitored byusing activity checklists. As no two projects are the same,we select from a wide range of tools and techniques todevelop a bespoke approach for each project.InitiationJump to:ConceptDesignValidation Teams Index Machines IndexMechanical& ElectricalDesignDesignThinkingAnalysis &VerificationStage Gate3D & 2DVisualisationPrototypingLearnings4

DPG technical capabilitiesDesign ThinkingThe Design & Prototyping Group applies the latest research tothe design process to create a hybrid design methodology, calledStoryboard Design. The technique allows designers to overcomecritical issues faced in new product development, which include: Avoiding fear of judgement. Cognitive Inertia- where familiar assumptionsaren’t challenged. Production Blocking – the tendency for one individual’sideas to dominate during a group discussion. Social Loafing – where some people working ina group put in less effort than if they were workingon their own.Jump to: Teams Index Machines IndexThe process also takes account of the availability ofequipment to produce low cost prototypes in the earlyphases of the design, reducing the likelihood of ‘sunk costthinking’ where investment in what has already been doneinfluences future decisions.Storyboard design is a fast, clean and efficient wayof producing a number of unique ideas that can beincorporated in complete product designs.5

DPG technical capabilitiesDesign for Additive ManufacturingThe Additive Manufacturing (AM) process allows complexdesign geometries to be produced in polymers and metals.Additive Manufacturing has been seen as a slow,expensive process that produces components thathave uncommon characteristics, and are limited to asingle material.Neither the AM systems, nor the supporting design tools,are mature and some designers’ thinking hasn’t adaptedto the possibilities of AM technology.We are swiftly addressing these issues by: Working with additive processes. Becoming specialists in the application of thepolymer fused deposition modelling (FDM) technique. Pushing the capability of machinery. Bridging gaps in AM knowledge.Jump to: Teams Index Machines Index6

DPG technical capabilitiesAnalysisOur Finite Element Analysis and Computational Fluid Dynamicstools allow us to undertake a variety of analytical tasks. We havethe capability to develop and validate analyses for many structural,fluid flow and thermal design questions.Our HyperWorks software suite allows us to create goal driven optimisationstudies using tools such as shape morphing or topology optimisation. Thesetools can create designs which mimic biological organisms, such as dragonflywings, bird bones and other organic structures.Jump to: Teams Index Machines Index7

DPG technical capabilitiesMechanical DesignThe Design & Prototyping Group has a broad range ofengineering expertise, including expertise in the road,rail, heavy industry and product design fields.This allows our team to respond to a variety of project requirementswith confidence. In house developments have included our globallyrecognised 3D printed Unmanned Aerial Vehicle (UAV), a complextwo speed miniature gearbox and a high precision residual stress drill.Jump to: Teams Index Machines Index8

DPG technical capabilitiesElectrical DesignThe electronics team has the experience to develop solutions from“proof of concept” through to “manufacturing ready prototype” in a waythat is aligned to your manufacturing and testing methods and the corefunctional requirements. A robust methodology within a Stage Gatedevelopment process is used to deliver a high value design serviceat minimum risk.Capabilities range from rapid proof of concept investigations using commercial, off the shelfhardware and Intellectual Property re-use through to detailed custom Field-ProgrammableGate Array/Printed Circuit Board (FPGA/PCB) level design with associated embeddedsoftware. The design methodology is complemented by a range of state of the art softwareapplications which enable effective management of multiple design constraints, pre/postlayout simulation, and rigorous validation.ProblemStatementJump to:Proof ofConceptCustomDesign Teams Index Machines IndexManufacturingReadyPrototype9

DPG technical capabilitiesMedical AMRCThe Medical AMRC is building upon the proven successful AMRC modelapplied to aerospace and high value manufacturing improvements,and focusing this approach to the healthcare industries. The group aimsto improve and bring new manufacturing and materials technologies tohealthcare and medical device companies through innovative design.The team includes experienced engineers, product designers,software specialists, and material scientists from a wide range ofindustrial and academic backgrounds, with experience of solvingproblems through engineering design and product development.The Medical AMRC has close links to research from theUniversity of Sheffield’s engineering and healthcare departments,teaching hospitals and clinical resources, as well as drawing onthe expertise and resource across the AMRC.The Medical AMRC’s CT Scanner, Metal Additive machine andCleanroom is based within the Design, Prototyping & TestingCentre workshop, which has a range of advanced machinetools and additive manufacturing facilities which complementpossible medical device manufacturing requirements, furthersupplemented with the wider AMRC’s available technology.With Additive Manufacturing in mind, the Medical AMRC areusing new design approaches to create innovative implantsand improve manufacturing capabilities using state-of-the-artadditive layer manufacturing technologies in metals andpolymers. They also aim to explore how design could be usedto reduce production time and costs, as well as to improve partperformance, to add value to the manufacturing industry.In combination with computerised tomography (CT Scanning),the Medical AMRC is researching the optimal way of designingfor, and manufacturing, medical parts to bring new, usablemanufacturing technologies to industry. The Medical AMRC willpush these technologies to their limits in terms of performanceand materials selection, as well as aiding SME’s to carry outnon-destructive analysis of manufactured component parts invarious materials.For more information, contact:Derek Boaler, Head of Medical AMRCd.boaler@amrc.co.ukJump to: Teams Index Machines Indexwww.medicalamrc.com10

AMRC Design & Prototyping GroupResources overviewResourcesThe following pages give full details for each of our core machining centres,housed in the AMRC Design Prototyping and Testing Centre. Click page to jumpLaser cutting Trumpf TruLaser 5030 fiber page 12Milling DMU 50 Ecoline page 13 DMG Sauer Ultrasonic 10 page 14Grinding Blohm Jung Profimat MC607 page 15Additive manufacturing 3D Systems ProJet 6000SD page 16Stratasys Fortus 900mc page 17 Stratasys uPrint SE Plus page 18 Stratsys Mojo page 19 Renishaw AM250 page 20Visualisation Virtalis ActiveWall page 21CT scanning Nikon Metrology XTH 225 LC page 22Jump to: Teams Index Machines Index11

Laser cuttingDPG machining resourcesTrumpf TruLaser 5030 fiberLaser cutter for thin and thick sheet metal.The TruLaser 5030 is a high-performance laser cuttingmachine capable of high precision on thick metal sheets.The machine features a 3 kW TruDisk 3001 fibre-guidedlaser with a beam quality of 4 mm mrad.Jump to: Teams Index Machines IndexType2-axis fibre laser cutterX-axis travel3000 mmY-axis travel1500 mmZ-axis travel115 mmMax material thicknessMild steel: 20 mmStainless steel: 15 mmAluminium: 15 mmCopper: 6 mmBrass: 6 mmMax axis speed (simultaneous)265 m/minMax laser power3 kWLaser beam quality4 mm mradAdditional functionalityAir and Titaniumcutting capability.12

MillingDPG machining resourcesDMU 50 EcolineUniversal milling machining for five-sided machining.The DMU 50 offers accurate five-sided machining ofcomplex workpieces. The patented NC swivel rotary tableenables an accuracy of up to 0.008 mm on the directmeasuring system, or 0.02 mm for indirect measuring.Jump to: Teams Index Machines IndexType3 2 axis milling machineX-axis travel500 mmY-axis travel450 mmZ-axis travel400 mmB-axis travel-5 to 110 Rapid traverse2,160 /minClamping surfaceØ630 x 500 mmLoad height790 mmMax table load200 kgMax torque83 NmMax power13 kW13

MillingDPG machining resourcesDMG Sauer Ultrasonic 10High-precision milling with ultrasonic machining for themost challenging materials.The Sauer Ultrasonic 10 combines high-precision millingcapabilities with advanced ultrasonic machining.By oscillating the cutting tool at ultrasonic frequencies,it can precisely drill and grind hard-to-machine materials,including glass, with very low process forces.The Ultrasonic can produce an extremely high qualitysurface finish (Ra 0.1μm for some materials) withreduced micro-cracks, and is ideal for thin-walledstructures. The centre has been designed for medicaland dental, tool and mould-making, watches, aerospace,pumps and valves, and optics applications.Jump to: Teams Index Machines IndexType5-axis simultaneous,ultrasonically assistedmilling machineX-axis travel120 mmY-axis travel120 mmZ-axis travel200 mmA-axis travel-10 to 120 C-axis travel360 Max spindle speed40,000 rpmMax torque1.6 NmMax power6 kW14

GrindingDPG machining resourcesBlohm Jung Profimat MC607Flexible grinding centre.The Profimat MC607 is a compact but flexible grindingcentre, capable of precision, profile, internal or externalcylindrical grinding.Jump to: Teams Index Machines IndexType5-axis simultaneous continuousdress grinding machineX-axis travel700 mmY-axis travel650 mmZ-axis travel520 mmMax spindle speed8,000 rpmPower52 kW15

Additive manufacturingDPG machining resources3D Systems ProJet 6000SDProfessional stereolithography for the toughest applications.The ProJet uses the well-established resin stereolithographytechnique to produce high-precision prototypes andshort-run parts in up to five VisiJet SL materials.Jump to: Teams Index Machines IndexTypeResin stereolithography additivemanufacturing machineX-axis travel250 mmY-axis travel250 mmZ-axis travel250 mmLayer resolution0.125 mmModel materialsVisiJet SL HiTempVisiJet SL BlackVisiJet SL ClearVisiJet SL FlexVisiJet SL ImpactVisiJet SL JewelVisiJet SL Tough16

Additive manufacturingDPG machining resourcesStratasys Fortus 900mcLarge, flexible 3D-printing centre for high-performance plastics.The Fortus 900mc builds large, accurate and repeatableparts from high-performance thermoplastics. In additionto demanding 3D-prototyping applications, the Fortus issuitable for creating fixtures, tooling and end-use parts.It offers a choice of three layer thicknesses and ninematerial options.Jump to: Teams Index Machines IndexTypeFused deposition modelling(FDM) machineX-axis travel914 mmY-axis travel610 mmZ-axis travel914 mmLayer resolution0.330 mm / 0.254 mm / 0.178 mmAccuracy 0.09 mm absolute accuracy,or 0.0015 mm per mm build(whichever is greater)Model PSFULTEM 908517

Additive manufacturingDPG machining resourcesStratasys uPrint SE PlusFlexible 3D-printing for rapid prototyping and modelling.The uPrint SE Plus is a flexible FDM machine capableof creating durable, stable and accurate models andfunctional prototypes. It offers two layer thicknessesand uses ABSplus thermoplastic in a choice of colours.The CatalystEX software converts standard CAD filesinto 3D modelling print paths, including any necessarysupport structures.Jump to: Teams Index Machines IndexTypeFused deposition modelling(FDM) machineX-axis travel203 mmY-axis travel203 mmZ-axis travel152 mmLayer resolution0.254 mm / 0.330 mmModel materialsABSplus in nine colours18

Additive manufacturingDPG machining resourcesStratsys MojoDesktop 3D-printing of professional-quality models.The Mojo is a professional-quality desktop 3D printer,capable of creating small concept models and rapidprototypes in ABSplus thermoplastic.Jump to: Teams Index Machines IndexTypeFused deposition modelling(FDM) machineX-axis travel127 mmY-axis travel127 mmZ-axis travel127 mmLayer resolution0.178 mmModel materialsABSplus in nine colours19

Additive manufacturingDPG machining resourcesRenishaw AM250 - Direct Metal Laser SinteringForms the most challenging of geometries,impossible through conventional processes.The Renishaw AM250 is capable of CAD driven directadditive manufacturing in a range of medical grademetals. The technology is driven through a high powered200 W ytterbium fibre laser which allows for fine metallicpowders to be fused, to form the most challenging ofgeometries, impossible through conventional processes.Type200 W Direct Metal Laser Sinteringmanufacturing machineBuild envelope245 x 245 x 360 mm (X, Y, Z)Layer resolutionLayer thicknesses available in30, 50 or 60 micronAccuracyDimensional accuracy geometrydependant.Typical Medical Applications: Surgical instrument kit manufacture.Customisable laser processthemes to achieve specificsurface finishes 5 to 30 Ra andthin walls 0.3 mm Patient specific orthopaedic implant designand development. Reconstructive surgical aids for maxillofacialor cranial application.MaterialTi6AL4V powder grade 23Additional materialsInconel 718,Stainless Steel 316L, CobaltChrome and Aluminium AlSi10 MgBuild ratesup to 20 cm³ p/hr Cadaver training guides and test product. Reverse engineering applications. Component weight reduction.Fully dense components to near net shape manufactureProcessing of components within a high purity Argon atmosphereat less than 100 parts per million oxygen levels Minimal materialwaste as over 98% of powder is re-usable post processingJump to: Teams Index Machines Index20

VisualisationDPG machining resourcesVirtalis ActiveWallImmersive, interactive virtual reality environment.The ActiveWall is a large screen wall with 3D backprojection for presenting virtual environments to smallgroups. Its operating system is compatible with a widerange of datasets, and the ActiveWall be used for designreviews, virtual assembly, training, factory layout,simulation, and many other tasks.Virtual Reality (VR) takes the risk out of change.VR allows experimentation in a safe environment,independent of scale, giving the user greater flexibilityand reducing the cost of change.The AMRC has five virtual reality facilities across itssite, which can be linked together to create a singleenvironment experience. The Design & PrototypingGroup’s system is also part of a cross-centre High ValueManufacturing Catapult project to allow Visualisation andVirtual Reality (V/VR) facilities at the seven Catapultcentres of excellence to be networked.Its integrated, networked approach to V/VR will allowpartner companies, local SMEs internal Catapult projectsand other Catapult centres to use the facilities as ‘local’delivery nodes, reducing the cost, time and environmentalimpact of collaborative projects.TypeImmersive 3D interactiveenvironmentScreen size4mx3mProjectionChristi Mirage S 6kTrackingIntersense IS-900The Government-backed Catapult helps companies ofall sizes to develop new technologies so that they becomecommercial realities.Jump to: Teams Index Machines Index21

CT ScannerDPG machining resourcesNikon Metrology XTH 225 LCCT scanning provides vital non-destructive informationto aid design optimisation.X-ray computational tomography is an essential capabilityfor developing design and manufacturing processes fornew technologies.Insight into organic and inorganic structures providescritical information which feeds back into designoptimisation. Non-destructive inspection of complexinternal structures. Measure internal dimensions with high accuracywithout sectioning part. Inspect porosity and defects for developing newdesign processes for additive layer technologies.Type225 kV / 225 W micro focusX-Ray source (Multi-metal target)Resolution3 – 200 micronDetectorPerkin Elmer 1620 flat panel16-bit detector(2000 x 2000 pixels)Geometric magnificationup to x150Sample weightup to 50kgScanned artefact dimensionsup to 600 mm (height) x 600 mm(diameter)Image processing andreconstructionVGStudio MAX 2.2 Inspect internal structures of a wide range of materials– composites, metals, polymers, ceramics, bone, foams.Jump to: Teams Index Machines Index22

AMRC with BoeingAdvanced Manufacturing ParkWallis WayCatcliffeRotherhamS60 5TZe: enquiries@amrc.co.ukt: 44 (0)114 222 1747w: amrc.co.uk

High-precision milling with ultrasonic machining for the most challenging materials. 14 Type 5-axis simultaneous, ultrasonically assisted milling machine X-axis travel 120 mm Y-axis travel 120 mm Z-axis travel 200 mm A-axis travel -10 to 120 C-axis travel 360 Max spindle speed 40,000 rpm Max torque 1.6 Nm Max power 6 kW DPG machining .

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