News: Metalysis doubles Gen 2 R&D demonstration units

Metalysis, the end-to-end manufacturer of solid-state metal and alloy powders and global leader in materials science, is increasing its output of specialist metals amid growing pressure to reduce reliance on Chinese supply chains.

With a Materials Discovery Centre on the Advanced Manufacturing Park (AMP) in Rotherham, the company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits.

Earlier this year, Rothbiz reported on the increasing in Gen 1 research units, which can produce grammes of output per machine per run. Metalysis has now doubled its Gen 2 units which enable transition from grams to kilograms-scale output.

The move is to meet unprecedented demand from advanced industries, including electronics, hypersonics, defence, clean energy and space. This expansion supports customers developing next-generation materials and reflects heightened urgency to secure non-Chinese midstream processing options following ongoing uncertainties surrounding new Chinese export controls on critical minerals and rare earth elements, first enacted in April.

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Nitesh Shah, CEO of Metalysis, said: “We are delighted to be doubling our Gen 2 units, just seven months after we increased our Gen 1 capacity by 1/3. We are seeing increasing demand for our products at the Gen 2 level, sending material to clients for evaluation and qualification into specialist markets, with particular interest from sputtering target manufacturers.

"A range of advanced manufacturing sectors come to Metalysis because of our core suite of products - capacitor grade tantalum, scandium tri-aluminide (Al3Sc), niobium alloys and our ability to create lightweight refractory high entropy alloys, and because clients know that with all the materials that we produce we bring unique and bespoke physical and chemical attributes to the end-material, meaning we are without competition across a range of products."

China continues to dominate mining and midstream processing, with 90 per cent of global midstream capacity. To reduce this dependency, Western nations are urgently seeking alternative processing solutions. Metalysis is well-positioned to fill this gap, offering scalable midstream capability across a wide range of critical materials.

Shah added: "The recent REE controls by the Chinese have accelerated this process as clients require metal feedstocks and midstream processing from outside of China, and this will be the dominant trend across critical materials over the next few years."

Metalysis website

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News: Tech firm opens new office on AMP in Rotherham

Industrial automation and robotics specialist, Loop Technology, has selected the Advanced Manufacturing Park (AMP) in Rotherham as the location for a new office as it continues to expand across the UK.

The firm specialises in machine vision, motion control and industrial robotics. Its FibreLINE system provides end-to-end automated preforming, revolutionising the production rate for carbon fibre structures and other composite parts and components. Additional systems include highly accurate robotic machining and automated laser cleaning.

Loop Technology has its HQ in Dorchester, Dorset and an additional office in Bristol.

Having joined the University of Sheffield Advanced Manufacturing Research Centre (AMRC) in 2022, Loop Technology sees South Yorkshire as a strategic location given that it works in the high value manufacturing sector including aerospace, defence, and renewable energy.

The 13,700 sq ft facility, part of Harworth's Revolution Phase 4 development, is just a few minutes away from the AMRC and the new COMPASS facility which aims to help UK industries to adopt more efficient, sustainable and cost-effective manufacturing solutions. Loop Technology continues to progress on the Isothermic High Rate Sustainable Structures project, with Boeing, Spirit AeroSystems and the AMRC.

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Alun Reece, CEO of Loop Technology, said: "Due to a big upswing in orders, Loop Technology had to execute a rapid expansion plan. Several sites were considered but the standout was the Advanced Manufacturing Park. With modern, energy efficient factory space ready for occupation and abundant local talent the Sheffield / Rotherham conurbation provided everything we were looking for. And I’m pleased to say its been everything we were hoping it would be.

"We’re building a great, highly skilled team of people there and I’m excited to see how we continue to develop the facility in the coming years.”

Composites at Speed and Scale (COMPASS) is a major boost to aerospace R&D in the UK. The 29,700 sq ft research facility is located next to the AMRC’s flagship Factory 2050 facility on the site of the former Sheffield Airport.

The facility will pioneer a new era in composite manufacturing by offering open access to a state-of-the-art, fully automated closed-mould cell of 10m x 3m for research purposes. This will enable single components to become larger, with complex sub-assemblies of up to ten metres becoming a reality – reducing cost, preventing delays and saving time.

The project with Boeing, Loop Technology and Spirit AeroSystems aims to de-risk and develop high-rate sustainable structures, with the potential to reduce large component process times from 40 hours to four hours.

Loop Technology website

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News: Defence Growth Deal for South Yorkshire

South Yorkshire is set for a boost through the launch of a £250m fund for Defence Growth Deals which will improve collaboration, foster innovation and create jobs in areas with untapped potential.

The Defence Industrial Strategy sets out how gonvernment spending on defence can benefit local economies, from highly skilled engineering positions to apprenticeships for young people starting their careers.

Initial analysis indicates there could be an additional demand of up to 50,000 defence jobs by 2034/35 with increases in defence spending. Defence Growth Deals will play an important role in capitalising on that skilled employment potential for communities across the UK.

South Yorkshire is one of five deals that will be backed by a total of £250m of defence spending over the next five years, underpinned by this Government’s historic increase in defence spending to 2.6% of GDP by 2027 and the ambition to hit 3% in the next Parliament.

They will forge long-term partnerships between national, devolved and local government, uniting businesses and research institutions to harness local expertise and resources in defence and the dual-use sectors. They will support the UK Armed Forces and deliver benefits for working people through the government’s Plan for Change.

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Defence Secretary, John Healey MP said: "The Defence Industrial Strategy will make defence an engine for growth across the UK, backing British jobs, British industry and British innovators.

"Defence Growth Deals offer a new partnership with UK Defence to build on industrial and innovation strengths that regions already hold. Together we aim to drive an increase in defence skills, SMEs and jobs across all four nations.

"We want to make the UK the best place in the world to start and grow a defence firm and will put Britain at the leading edge of innovation."

The new fund builds on the success of the Plan for Barrow. The deals, created in partnership with industry, local government and other regional organisations, will see investment in that area’s sub-sector specialisms, harnessing their ingenuity and mass, while also launching specific interventions that help support that defence ecosystem and the places themselves, delivering long-term and sustainable regional growth across the UK.

South Yorkshire is identified as a key hub for the development and engineering of high integrity, precision materials for the defence sector, including at MOD-owned Sheffield Forgemasters.

The region is also home to the University of Sheffield’s world-leading Advanced Manufacturing Research Centre (AMRC) which has multimillion pound facilities on the Advanced Manufacturing Park (AMP) in Rotherham. A growing defence cluster is being bolstered by BAE Systems new artillery factory in Sheffield.

The strategy set out that in South Yorkshire, "we will further leverage the region’s strengths in the research, development and engineering of high-grade components and materials critical to the next generation of maritime, land and air capabilities."

South Yorkshire Mayor Oliver Coppard, said: "South Yorkshire has always been at the forefront of our country's security. We supplied munitions in both world wars, we are the home of the Vulcan and we are helping to build the submarines of tomorrow at Forgemasters in Sheffield. Now, the government has asked us to do even more to keep this country safe as we face up to the challenges of an evermore uncertain future.

"The Defence Growth Deal we've just been awarded isn't just a critical part of the UK's new Defence Industrial Strategy, it's a vote of confidence in the work we do here in South Yorkshire, from quantum computing to material science. That deal will offer very real opportunities for companies across Barnsley, Rotherham, Sheffield and Doncaster. It will mean more secure, well-paid jobs and it will power the growth that will make us all better off."

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News: Rolls-Royce readying £21m investment in Rotherham facility

Rolls-Royce, one of the most famous names in engineering throughout the world, is preparing to invest in a £21.3m expansion project at its Advanced Blade Casting Facility (ABCF) in Rotherham.

The £110m facility on the Advanced Manufacturing Park (AMP) in Rotherham was officially opened in 2015 and is where turbine blades are manufactured for Rolls-Royce's world-leading aeroplane engines.

Following continued demand and thousands of engines on order, the firm is working on proposals to double the factory’s production capacity which is key to the manufacture of single crystal (SX) turbine blades.

With an initial capacity of 100,000 blades per year, it was always likely to increase to 200,000 when the pioneering manufacturing process had been proven.

The ABCF has a prime position within the South Yorkshire Investment Zone and so the South Yorkshire Mayoral Combined Authority (SYMCA) is looking to support Rolls-Royce with a grant, potentially up to £2m.

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Allthough SYMCA meeting papers do not name the beneficiary company, the information all points to Rolls-Royce.

Papers say: "IZ002 [the company] is currently undergoing a major transformation which began in 2023 and is anticipated to complete by 2027, with particular focus on reducing operating costs.

"The Facility in Rotherham is a cutting-edge supplier of high-value superalloy turbine blade castings. IZ0002 load and capacity planning forecasts a demand increase of circa 100,000 single crystal turbine blade castings per year between 2024 and 2030, with existing factory capacity exceeded in 2026. The investment proposal is for a £21.3m investment in the facility to double the factory’s production capacity.

"The proposal includes £18m of capital investment, primarily for tooling and precision machines, including adaptive robotic aerofoil finishing (the latest and most advanced manufacturing technology for this process)."

Investment Zone status provides South Yorkshire with up to £160m over ten years which can be used to offer investors, developers and start-ups a combination of targeted support and financial interventions to start, scale up and relocate their businesses.

In SYMCA budget papers, a "Rolls Royce - Expansion of blade manufacturing research and innovation" project has been given a total of £1.75m.

Rolls-Royce launched a bold, multi-year transformation programme in 2023 focusing on cost efficiency, commercial optimisation, and operational improvements. The company's underlying operating profit for the 2024 financial year was £2.5bn.

Rolls-Royce website

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News: McLaren makes a revolutionary leap in composites at Rotherham tech centre

Building on over 40 years of carbon fibre innovation, McLaren has unveiled a world-first in supercar engineering: aerospace-derived Automated Rapid Tape (ART) carbon fibre. And it has been developed in Rotherham.

The manufacturer opened the McLaren Composites Technology Centre (MCTC) in 2018 on the Advanced Manufacturing Park (AMP), which is in Rotherham. The £50m investment was made in developing and manufacturing the future of lightweighting technology.

The latest revolutionary leap in composites uses precision manufacturing techniques from the aerospace industry to create carbon fibre structures that are even lighter, stiffer, and stronger, while reducing waste by up to 95%. It is a world-first application of a cutting-edge and highly specialised manufacturing process in the automotive sector.

The first model to feature this advanced material is the McLaren W1 – where ART carbon integrated into the active front wing delivers a 10% boost in stiffness to help enable the car’s extraordinary aerodynamic performance.

The aerospace industry uses ultra-precise manufacturing methods to build highly tailored carbon fibre structures for the latest generation of air jetliners and fighter aircraft, particularly for large, crucial parts such as aircraft fuselage and wings. This is achieved via the robotic depositing of composite tapes to layer structures, over traditional hand layup using pre-impregnated materials. And it is a rapid pace, ‘high rate’ version of this production method that McLaren has developed and now integrated into its manufacturing capabilities at the McLaren Composites Technology Centre (MCTC) in Rotherham.

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Completely revolutionising the aerospace industry method of using robotic arms to layer composite tapes, McLaren’s Automated Rapid Tape method instead employs a specially designed machine using a fixed deposition head and a rapidly moving bed capable of rotation, which unlocks a faster manufacturing process suitable for automotive purposes and high-rate composites manufacturing.

Joe Elfort, plant director at the McLaren MCTC, said: "It means we can make the material as strong as possible where it needs to be and as light as possible where it can be. Think of it like human skin - it can be thin and flexible like your eyelids but also strong and durable like your elbows.

"With this new technology we've taken an aerospace scale manufacturing process and enhanced the rate capability so that it becomes viable for a supercar component. What's really unique is we can very accurately control the directionality of the strength the stiffness and the flexibility which allows us to optimise the design for the highly loaded and complex components like you see in the aerodynamic devices of the W1.

"Landmark supercars like W1 always usher in the next big technology trickle down. This is only the beginning of a remarkable new era in lightweight supercar engineering and performance."

The advantages Automated Rapid Tape technology can deliver in terms of manufacturing time and reduced costs creates the possibility of greater use of carbon fibre, in more areas of a vehicle. Looking beyond the carbon tub, wider use of ultra-lightweight body panels constructed of McLaren ART carbon fibre become more feasible and cost effective.

The Artura is McLaren’s first model to be built on all-new McLaren Carbon Lightweight Architecture (MCLA) that was developed in Rotherham. The latest advancement now unlocks immense possibilities for the next generation of carbon fibre architectures. Integrating ART technology into the structure of an ultra-lightweight, ultra-strong carbon fibre tub – manufactured with minimal waste material generation - that can underpin the next-generation of McLaren supercars is already under consideration.

McLaren website

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News: Magtec secures funding for submarine propulsion project

Rotherham-based Magtec, the UK’s leading innovator in electric driveline technology, has secured funding through the Defence Technology Exploitation Programme (DTEP) to deliver a world-first in nuclear submarine propulsion. This game-changing project will push the boundaries of stealth, power efficiency, and operational capability, cementing Magtec’s role in the future of defence engineering.

Through this collaboration with MacTaggart Scott, Magtec will develop Permanent Magnet Motors (PMM) for 26 advanced submarines, drastically reducing engine noise, heat emissions, and overall size. This breakthrough will transform the Royal Navy’s fleet into silent warriors beneath the waves, making detection by adversaries exponentially harder.

Magtec will receive a government grant worth 50% of the project value with the aim of developing innovative new solutions that meet UK defence challenges and increase capability in the UK defence supply chain.

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Magtec is a leading UK designer, manufacturer and integrator of electric and hybrid drive systems for customers in the defence, rail and commercial sectors. The company is a member of the British Army’s programme to develop technologies for battlefield electrification and holds an Armed Forces Covenant Bronze Award in the Employer Recognition Scheme. Founded in 1992, Magtec is privately owned and headquartered at a bespoke design and manufacturing facility in Templeborough.

A submarine’s ability to remain undetected determines its effectiveness in surveillance, deterrence, and combat. Traditional propulsion systems generate noise and heat signatures that can be tracked by enemy forces. Magtec’s next-generation Permanent Magnet Motor technology will virtually eliminate these vulnerabilities, giving UK submarines an unrivaled tactical advantage.

Marcus Jenkins, Chief Technical Officer at Magtec, said: “This isn’t just an improvement—it’s a complete shift in how submarines will operate. Our Permanent Magnet Motors will deliver unmatched power and efficiency while slashing weight, noise, and maintenance needs. This is a monumental advancement in defence technology, and we’re proud to be leading the charge.”

Andy Gilligan, Managing Director at Magtec, added: “Magtec has always been at the forefront of electrification, and this project is proof of our ability to deliver world-class defence solutions. The technology we’re developing will provide the Royal Navy with an operational advantage that was once thought impossible.”

Magtec website

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News: Green hydrogen company joins innovation community on AMP

WD HydroTech, a fast-growing green hydrogen company, has taken workspace on the Advanced manufacturing Park (AMP) in Rotherham.

At the AMP Technology Centre, the start-up joins a cluster of advanced manufacturing, and engineering businesses co-locating in South Yorkshire’s Investment Zone.

AMP Technology Centre offers lab, workshop, office and meeting space in the heart of South Yorkshire’s innovation community. The workspace and surrounding AMP are home to world-class research facilities, global brands, targeted skills development programmes, and a network of experts commercialising research and growing businesses.

WD HydroTech is a research and development company focused on improving electrolyser and hydrogen gas compression technology to support the green hydrogen supply chain. Incorporated in August 2021, WD HydroTech is the brainchild of Founders Dr Nigel Williamson and Keith Downes, who started the business from Nigel’s garage three years earlier. Combining their extensive experience in engineering and bringing new technologies to market, with a passion for sustainable energy solutions, they are developing a novel solution for green hydrogen generation and compression.

In September 2024 the duo and their growing team, which includes Head of Operations Heidi Tomlin and Engineering Manager Mark Walker, were awarded the highly competitive Innovate UK Smart Grant. The government-backed investment raised half a million pounds and has been the catalyst to secure onward investment, catapulting the start-up from proof-of-concept prototype, to the next round of pre-seed funding and onwards to real-world product testing.

Over the next 12 months WD HydroTech will expand operations and triple the team size from their specialist unit at AMP Technology Centre.

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Head of Operations Hiedi Tomlin, said: “We looked for a suitable workspace across North Derbyshire and South Yorkshire and were attracted to AMP Technology Centre because uniquely they could offer us room for engineers to prototype, manufacture and test products for industry, alongside the business-critical commercial meeting and office space that is so essential for a fast growing start-up like ours.

“The business community that is co-located here and our proximity to the Catapult Advanced Manufacturing Research Centre (AMRC) and their Training Centre was another major draw. The world class apprenticeship programme established here can deliver a steady pipeline of highly skilled talent for our growing business.

“We’ve already started to have useful conversations with our neighbours, and we value the opportunity to build these local networks and relationships within a space like AMP Technology Centre.”

The global application and potential for green hydrogen is huge but for a long time the challenge for producers and suppliers has been reliable and sustainable production and storage. The challenge for end users is often accessibility and price. With their green hydrogen electrolyser and gas compressor technology WD HydroTech will address these challenges directly, improving accessibility and affordability for green hydrogen across markets.

WD HydroTech website
AMP Technology Centre website

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News: New £3m South Yorkshire Innovation Programme to help business innovate and grow

Rotherham businesses can access opportunities to engage in and benefit from innovation-led growth, driving innovation led activities.

The South Yorkshire Innovation Programme (SYIP), a collaboration led by Sheffield Hallam University with the University of Sheffield and Barnsley Council, is backed by £3m via the South Yorkshire Mayoral Combined Authority (SYMCA) has been co-designed and developed with each of the four South Yorkshire local authorities.

SYIP will provide opportunities for businesses to engage in and benefit from innovation-led growth, driving innovation led activities. It will build upon a successful track record of delivering innovation support to SMEs in the region.

The programme will provide access to high-quality and bespoke innovation support including academic consultancy, innovation audits, student projects and placements, access to university equipment and facilities, events and technical workshops.

Support will be available to organisations of all sizes across all sectors based in South Yorkshire, including charities and social enterprises. Further details on the launch of the programme and how organisations can access support will follow later this year.

The project is one of several partnerships between Sheffield’s universities, local authorities and SYMCA aimed at driving economic growth and inward investment into South Yorkshire.

Others include the Sheffield Innovation Spine, a long-term spatial and economic strategy to create and link the infrastructure required to grow knowledge-led businesses and the Innovation Network South Yorkshire which brings together academics, businesses and organisations at free networking events to encourage collaboration.

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South Yorkshire’s Mayor, Oliver Coppard, said: “We are getting on with the job of building a bigger, better economy in South Yorkshire. But we can’t build a new future without new ideas.

“That’s why it’s vital we bring together our world-leading universities and local authorities to help our local businesses harness innovation. The South Yorkshire Innovation Programme will help our businesses to create the future here, right here.

“I’m determined to build a South Yorkshire that works together to spread wealth, opportunity and success to all our communities.”

Professor Rory Duncan, Pro Vice-Chancellor for Research, Innovation and Knowledge Exchange at Sheffield Hallam University, said: “At a time of rapid advancements across an ever-increasing range of sectors, the ability to innovate and harness new technology is more important than ever for businesses of all sizes.

“Sheffield Hallam is delighted to be leading this new programme fostering stronger partnerships between academia and business. This collaboration aims to translate cutting-edge research and knowledge into tangible solutions that address the unique challenges of our region’s businesses."

Professor Ashutosh Tiwari, Deputy Vice-President for Innovation at the University of Sheffield, said: “The University of Sheffield has a proven track record of partnering with local organisations to drive innovation and boost economic growth. This collaborative programme offers an exciting opportunity to build on our successes.

“We’re very much looking forward to working closely with some of South Yorkshire’s innovative organisations to help them adapt and thrive as the challenges they face continue to evolve. Together, we can turn our world-leading research into practical solutions to address the region’s specific needs, while strengthening South Yorkshire’s position as a hub for innovation.”

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News: Manufacturing breakthrough for Magtec

Rotherham-based Magtec, a pioneer in electric vehicle drive systems, has successfully completed two industrial research projects, both matched-funded by the UK government and delivered through the Advanced Propulsion Centre UK (APC).

The strategic programmes focused on the production scale-up of Magtec’s class-leading traction motors and controllers with the aim of transforming manufacturing processes and product designs to achieve volumes of more than 5,000 units annually and meet rapidly growing demand for electrification of commercial vehicles.

Prior to this activity, the Templeborough firm's innovative electric drivetrain technologies were firmly established within the electric truck, bus and commercial vehicle sectors, but with their complex designs and niche-volume requirements, assembly was primarily a manual process.

In 2020, the company secured match-funding of more than £5m through the APC’s Collaborative Research & Development funding stream.

Working in a consortium, which included transport OEMs Dennis Eagle and Angel Trains, the Manufacturing Technology Centre (MTC) and the University of Sheffield Advanced Manufacturing Research Centre (AMRC), Magtec was able to embark on a three-year project to reinvent manufacturing processes and future-proof manufacturing capacity while guaranteeing high quality and traceability.

Using advanced digital manufacturing principles, Magtec established new intellectual property that made its products easier and faster to manufacture at scale. This involved the introduction of new pilot production equipment, designed to prove-out agile automation while allowing for rapid reconfiguration, meaning all motor variants can now flow through the same production line with minimal disruption. Additionally, the project helped Magtec establish a robust UK supply chain for electrification, providing better security of supply as forecast volumes ramp up.

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In 2022, Magtec went on to secure additional APC match-funding of £2m through the Automotive Transformation Fund’s Scale-up Readiness competition. With this support, Magtec was able to reapply its acquired lean and digital manufacturing expertise to support the industrialisation of its controller systems, employing automation best practices, redesigning products and further developing UK supply-chain opportunities, to build a roadmap for volume manufacture of both motors and controllers.

Andrew Gilligan, managing director of Magtec, said: “Through the support of the APC, we are now better able to service fleets and OEMs in the UK, Europe and the United States as they transition to electric vehicles. We’ve transformed our manufacturing capabilities while maintaining the exceptional durability and performance that makes our systems ideal for demanding commercial uses.”

Matt Shillito, senior project delivery lead for the APC, added: “Magtec’s high performance electric drive train technology is now excellently positioned to seize a growth market opportunity. As demand for electric vehicles increases both for first-build and re-power applications, so does the need for versatile and effective powertrain systems like those offered by Magtec.

“Making these systems efficient and affordable is essential to enable decarbonisation of the range of commercial vehicles currently in use, while still delivering customer priorities like drivability, range and efficiency. It is exciting to see a UK company and its local supply chain partners gearing up to deliver these systems to the automotive sector at scale.”

Magtec website

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News: IntelliAM AI secures DIF Lighthouse Funding Award

A subsidiary of IntelliAM AI plc, the Rotherham software company leveraging the power of AI and machine learning in the manufacturing industry, has been named as a "Lighthouse for AI" and secures a Digital Innovation Fund (DIF) Lighthouse Funding Award of £263,000.

The Dinnington firm, which recently floated on the stock exchange, has developed a platform that can be used when determining optimum run speeds or machine settings, help with stock keeping and hygiene processes, and help predict and prevent component failure. The aim is to increase production levels and reduce downtime.

The funding is for a research project into the application of AI in lubrication analysis is made by The Smart Manufacturing Data Hub which is funded by Innovate UK.

IntelliAM AI recently acquired 53 North, a provider of a broad range of asset care consulting and management strategies for manufacturers, particularly in the fast-moving consumer goods (FMCG) sector, including McVities (Pladis), Mars, Diageo and PepsiCo.

IntelliAM AI has access to over 180 manufacturing sites in the UK and has lubrication analysis results for thousands of components from the last ten years. Lubrication is one of the key drivers of manufacturing downtime.

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Using IntelliAM’s existing data, and new data to be collected during the project, a machine learning model will be created to advise OEMs and SMEs on best practice lubrication for their components.

Software will be built that allows component information to be entered and the MLM will then create the grease and oil lubrication schedules automatically. Software will also be built that creates an on-condition lubrication schedule based on bearing condition.

An oil analysis result checker will be created, so that organisations can upload individual oil analysis results and compare themselves to our 10 years of history, specific to the environment and component types. Any issues will be highlighted and advice on action given.

This project will help reduce machine downtime on manufacturers equipment and create resilience against the reduction in engineering skills that we currently have in the UK. Sustainability will be improved as oil will only be replaced when needed.

This project will impact the Company on three fronts, namely improved internal productivity, new machine learning access to SMEs and a commercial product to increase sales.

IntelliAM website

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News: Redundancy threat at Nuclear AMRC

Staff at the Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) have been told of proposed redundancies with only core research & development activities to be retained.

With state of the art facilities on the Advanced Manufacturing Park (AMP) in Rotherham, the £25m Nuclear AMRC is a joint initiative with industry, The University of Sheffield and The University of Manchester's Dalton Nuclear Institute, and is designed to help build and enhance the UK's civil nuclear new build industry.

Hailed as being "fundamental in making the difference in the UK and winning vital orders" by the former Vice-Chancellor of the University of Sheffield, Professor Sir Keith Burnett, the insitution, and current vice-chancellor, Koen Lamberts, appear to be scaling back the centre as the wider industry suffers delays in both large and smaller scale nuclear investment projects.

Construction of the 86,000 sq ft centre at Waverley begun in November 2010. With over 100 staff, the workshop includes a range of state-of-the-art manufacturing equipment tailored for nuclear industry applications. The building also includes laboratory and technical support space, a VR cave for virtual assembly research and training.

With funding from industrial members (reactor providers such as Westinghouse, and top-tier suppliers such as Rolls-Royce and Sheffield Forgemasters) and government research and support grants, the centre has also developed a supply chain programme to help UK manufacturers get ready to bid for work in civil nuclear.

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Professor Koen Lamberts, Vice-Chancellor of the University of Sheffield, told The Times Higher Education: “To deliver our priorities around clean energy research and innovation, we have proposed changes to the current structure of the Nuclear AMRC. We are actively working to reduce the need for redundancies where possible and we are supporting our staff throughout the change process.

“The plans propose that the Nuclear AMRC’s core manufacturing research and development activities will be retained by the University of Sheffield.

“The proposed changes reflect the university’s key strength in nuclear manufacturing R&D. Our work to support the design and production of small modular reactors will continue to grow and offer significant opportunities for the South Yorkshire region.”

Large scale nuclear projects are behind schedule and over-budget despite a desire to increase nuclear energy capacity. For example, EDF's Hinkley Point C has been delayed by at least a further two years to 2029 at the earliest.

Focus has shifted to small modular reactors (SMRs) as a more deliverable option for nuclear power, but this sector has also been hit by delays.

Earlier this year, Andrew Storer, CEO at tne Nuclear AMRC called for more action. He said: "As many of the companies at our recent SMR supply chain events pointed out, they are waiting on decisions from government, Great British Nuclear (GBN) and the top-tier developers on which projects might be going ahead and on what timescale.

"The sooner that decisions are made and transferred to the supply chain, the sooner capability and capacity can be developed."

Rolls-Royce, a company intrinsically linked to the university and region, recenlty committed to a £multi-million Module Development Facility to produce working prototypes of the individual modules that will be assembled into Rolls-Royce SMR power plants. The facility is set to be develed inside the AMRC’s flagship Factory 2050 building in Sheffield and not at the Nuclear AMRC.

Nuclear AMRC website

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News: UKAEA and University of Sheffield partnership to drive fusion technology

The United Kingdom Atomic Energy Authority (UKAEA) and the University of Sheffield have entered a partnership that is set to drive the development of fusion technology and the UK’s future fusion industry.

The collaboration will see Sheffield appoint two Chairs in fusion research and development. Both roles will establish new research programmes to address global fusion challenges.

The position of Chair in Qualification for Fusion will address fundamental engineering challenges in the qualification of components, fabricated assemblies and systems for use within future fusion powerplants.

The position of Chair in Fusion Materials will focus on innovation in materials design and processing to improve powerplant performance and the decommissioning and recycling of new materials developed.

Both Chairs will work closely with UKAEA staff and the University of Sheffield Nuclear Advanced Manufacturing Research Centre (Nuclear AMRC) in Rotherham, part of the UK’s High Value Manufacturing Catapult, which helps to move cutting-edge research from universities into the commercial market.

The University’s Faculty of Engineering will host the two Chairs. UKAEA has chosen to work with the University because of its expertise and strong track record in materials science, engineering and manufacturing research, which are crucial for developing new low-carbon technologies.

As part of the partnership, UKAEA will also collaborate with the University’s UK-leading research in thermal hydraulics - a key research area in the development of fusion as an energy source.

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Dr Amanda Quadling, Director of Materials Research at UKAEA, said: “We are pleased to partner with the University of Sheffield. Their Department of Materials Science and Engineering has a combination of process innovation capabilities, metals performance testing and high calibre microscopy skills which will complement our post-irradiation activities.

“This partnership will help to address intrinsic engineering and materials challenges in order to make fusion energy commercially viable. It will also develop a pipeline of talent for the future of our thriving fusion industry.”

Professor Jim Litster, Vice-President for Engineering at the University of Sheffield, said: “Here at Sheffield we have a long track record of world-leading research excellence across materials science, advanced manufacturing, engineering, and low-carbon energy research. This is coupled with successful translation into industry and UK government policy.

“Developing strong external partnerships is a key part of our Faculty of Engineering’s strategy. With the University, UKAEA’s Fusion Technology Facility in Rotherham and the STEP prototype fusion powerplant site at West Burton, Nottinghamshire, all in relatively close proximity to one another, the partnership will develop a strong regional focus on fusion excellence in South Yorkshire and surrounding regions. Harnessing the research strength of northern universities, such as ours at Sheffield, is crucial if the UK is going to transition to low-carbon energy sources and protect its energy supply over the long-term.”

It is expected the two positions will attract collaborations from a wider range of industrial partners who will be able to sponsor students and work in partnership with them on research projects.

Stephen Wheeler, Director of Fusion Technology, UKAEA, said: ”The challenge of how we test and qualify components for future use in a fusion environment is critical for the delivery of a fusion powerplant. Partnering with the University of Sheffield to launch a new Chair in this field will accelerate the application of cutting edge techniques from across all sectors of engineering and the development of new experimental and digital techniques specific to fusion.

“The UKAEA’s Fusion Technology Facility based at the Advanced Manufacturing Park, South Yorkshire, is enabling us to access and grow regional capabilities to support the delivery of fusion. This includes local skills development from schools to universities and also the world class capabilities within the local manufacturing supply chain. We look forward to accessing the University of Sheffield’s expertise in engineering testing and qualification to enhance our national programme.”

Along with many other framework agreements with universities and industry partners, the agreement aims to bolster the UK’s strong position in commercialising fusion energy as a major source of low carbon electricity for the second half of this century.

Fusion is the process which occurs at the centre of stars; it is the source of light and heat emitted by the Sun.

Finance invested in fusion energy enables new materials and technologies to be developed that can benefit not just fusion energy, but also a wide range of industries including space, healthcare and decommissioning.

UKAEA’s mission is to lead the delivery of sustainable fusion energy and maximise scientific and economic benefit.

UKAEA website

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News: Cti joins the cast at AMRC

Internationally renowned castings company, Castings Technology International (Cti), has become a new partner of the University of Sheffield Advanced Manufacturing Research Centre (AMRC), recognising the ‘synergy’ between the two organisations and the value it will bring to its customers.

Based on the Advanced Manufacturing Park (AMP) in Rotherham, Cti is the world’s leading provider of production, innovation, technology, expertise and services to the cast metals sector. Sitting alongside the AMRC on the AMP, Cti provides advanced casting expertise and manufacturing capabilities, including computer process modelling, design for casting manufacture, rapid manufacture of precision castings, additive processes and materials research, for aerospace and other high-value manufacturing industries.

Managing director, Richard Cook, said: “With extensive multi-alloy manufacturing capability, unique consultancy services and a global network of foundry members, Cti is a ‘one stop shop’ for casting designers, users and manufacturers.

“Once a subsidiary of the AMRC, Castings Technology International is delighted to have become a member of this world-leading cluster of research groups. There is a great deal of synergy in what we do, in particular the ability to signpost clients from pure R&D towards the exploitation of newly developed technology and vice versa for those with mature products who are looking for R&D support.

“We relish the continued association with AMRC and the value that it will add to both Cti and our customer base.”



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Formed in 1996, following the merger of the British Cast Iron Research Association and British Steel Casting Research Association, Castings Technology International Ltd moved to a 5,000 m² workshop in Rotherham in 2006. In 2013, the University of Sheffield acquired the company and Titanium Castings UK Ltd to form CTI as a University subsidiary; funding was also secured to expand the facility to 1,200 m² and to house Europe’s largest titanium melting facility.

In 2021, the management team and the University of Sheffield agreed a management buyout with ownership transferred to the company’s existing management team, which operates it as a privately-run business.

Cti has become a Tier 2 member or the AMRC, part of the High Value Manufacturing Catapult, which allows it to participate in, and obtain the results of, all generic projects as well as being represented on the AMRC’s industrial board. Membership is open to any company which works in a complementary area or which wishes to participate in the support of the AMRC’s research programmes.

Ben Morgan, AMRC research director, said: “I am absolutely thrilled to have Cti formally join the AMRC membership. We have obviously had a very close and successful working relationship in the past and this membership will build on that firm foundation.

“Cti is going from strength to strength and its close integration with AMRC Castings is highly beneficial for both parties as well as the UK economy. Cti will continue to be a key pipeline to translate innovation into industry at this pivotal time in UK manufacturing.”

Founded in 2001 by the University of Sheffield and Boeing on the site of the former Orgreave Colliery in Rotherham, the AMRC now has centres in the North West and North Wales and is a model for collaborative research which is now being applied to the development of sustainable technologies and products to help its 120-plus industrial partners realise the benefits of a green transition.

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News: Magtec leads £3.25m project to turbo-charge take-up of zero emission trucks

Rotherham-based Magtec, the UK’s leading designer, manufacturer and integrator of drive systems for electric and hybrid vehicles, is heading a government-backed project to accelerate the adoption of zero emission trucks for NHS Wales and support uptake across the UK.

Backed by the Department for Transport and Innovate UK, the £3.25m project will create a predictive tool for making accurate comparisons for prospective electric vehicles within a fleet and estimating electric vehicle infrastructure requirements and costs, giving fleet managers the confidence to convert their fleets.

Magtec, which has recently expanded its premises at Templeborough, is working on the trial with Dynamon, the fleet data analytics specialist, and electrical infrastructure specialists UK Power Networks Services.

Magtec is supplying ten 18t zero emission electric trucks to NHS Wales. The trucks will be used to help with the collection and distribution of laundry at four locations across the country. The vehicles will be equipped with the ability for a rapid charge system for increased usability. Each of the chargers will also be mobile, meaning they can be easily moved around and connected to wall sockets installed by UK Power Networks Services.

Dynamon is developing its proven feasibility software – based on advanced artificial intelligence – to predict battery state of charge, road performance and grid load. UK Power Networks Services is developing a tool for estimating EV installation costs and installing charging infrastructure across the different NHS sites used in the trial: Bridgend, Cwmbran, Denbigh and Newport.

The first two vehicles begin road tests and enter service in the coming weeks.

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Andrew Gilligan, managing director of Magtec, said: “The move from internal combustion engine to electric vehicle fleets is disrupting procurement in the public and private sectors with uncertainty around costs and infrastructure.

“Fleet managers are under pressure to electrify their fleets but there is little data to support their investment decisions. This project will fill the gaps in knowledge and help accelerate the take-up of zero emission trucks, creating new jobs here at Magtec and across our supply chain in South Yorkshire.”

Transport Minister Trudy Harrison said: “This exciting project is an important step in our journey to reducing our reliance on fossil fuels as we introduce cleaner HGVs to our roads.

“The fleet industry plays a vital role in keeping the UK moving and it’s crucial it joins the journey to a greener future. That’s why I’m delighted to see Magtec benefitting from the Government’s £20m zero emission road freight trials and I look forward to seeing the outcome of this project as we invest in research to decarbonise all aspects of our transport network.”

For the Welsh government, Deputy Minister for Climate Change Lee Waters said: “It is great to see NHS Wales making a commitment to trialling electric heavy goods vehicles as part of its ambition to be net zero by 2030. I am also pleased to see the part it is playing in reaching our ‘Team Wales’ commitment, signed up to at COP26 last year, for at least 30 per cent of new medium and heavy duty vehicles sold in Wales to be zero emission by 2030.”

Kieran Coughlan, Head of Strategic Advisory Services at UK Power Networks Services, said: “This project is hugely exciting because it will demonstrate how large organisations in the UK can cost-effectively transition their fleet. It’s another tool we can use to support business to meet the financial hurdles of switching to electric vehicles, whether through financing, integrating new technologies, or optimising existing infrastructure.”

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News: AMRC's economic impact and influence on Rotherham, Yorkshire and the UK

Some of the biggest private sector investments into UK advanced manufacturing over the last 15 years ‘would not have happened without the AMRC’, according to a new report confirming it as a ‘signature asset’ having brought more than £260m and 600 jobs to South Yorkshire.

Founded in 2001 by the University of Sheffield and Boeing on the site of the former Orgreave Colliery in Rotherham, the University of Sheffield Advanced Manufacturing Research Centre (AMRC) now has centres in the North West and North Wales and is a model for collaborative research which is now being applied to the development of sustainable technologies and products to help its 120-plus industrial partners realise the benefits of a green transition.

In 2021 the AMRC celebrated 20 years of innovation, impact and investment. The Economic Impact Analysis report by Lichfields sets out how the AMRC is a magnet for capital investment, acts as a lever for improved social mobility through its training centre, and supports a 520-strong high-value workforce that contributes more than £55m to the economy.

An executive summary has been published ahead of a formal launch for the report, which captures the economic benefits attributable to the AMRC, part of the High Value Manufacturing Catapult, during its first 20 years of operation. It looks at the impact made through innovation, research and development (R&D), education and skills, high-value employment, levelling up, and being a model that can be ‘exported’ to other regions to stimulate economic regeneration.

It shows that in 2019/20, the value of innovation activity undertaken by the AMRC - supporting industry by delivering step changes in productivity, increasing competitiveness, and developing new products and processes - totalled £32.1 million. In addition, the centre unlocked a further £55.6 million of private sector leverage or match funding, supporting the UK government’s aim to double the value of private sector investment in R&D by 2030.

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In the new report, Rachel Clark, director of trade and investment at the South Yorkshire Mayoral Combined Authority, says: “The AMRC is a key attractor of foreign direct investment (FDI) and an important part of South Yorkshire’s pitch to prospective investors. Some of the biggest investments into the area over the last 10 to 15 years would not have taken place without the AMRC.”

It is the first time the AMRC has directly commissioned analysis into its impact, having been founded in 2001 at the heart of the Advanced Manufacturing Park in Rotherham by Prof Keith Ridgway and local businessman Adrian Allen, with critical support from the University of Sheffield and aerospace giant Boeing.

The first tenants on the Advanced Manufacturing Park (AMP), the AMRC has played a "key role in transforming the site into an attractive location for advanced manufacturing businesses", drawing major inward investors such as Rolls-Royce and McLaren which have built facilities in the area, and helping the local economy to emerge from the decline of its traditional industrial strengths of coal and steel.

Data shows on average, the AMRC provided manufacturing innovation and technology support to more than 1,100 businesses each year between 2017/18 and 2019/20, and 42% of those were small to medium-sized enterprises (SMEs). It is also identified as ‘an important employer’, supporting 520 high-value, high-productivity jobs in 2021/22 - generating a Gross Value Added (GVA) equivalent of £55.8m per annum.

Rotherham Council leader, Coun Chris Read, said: “The AMRC has been critical to securing major private sector investment in the borough, providing training, opportunities, and remarkable careers for our young people.

“From its iconic location on the former site of the Orgreave Coking Works, the University of Sheffield AMRC is not only a tremendous example of successful regeneration, but it is part of the fabric of our community, sitting at the heart of the flagship series of investments which are writing the next chapter of Rotherham’s economic history. “It is a partnership that we value highly and with the AMRC's knowledge and expertise, we can build on the growing cluster of green manufacturing in the region and support industry to drive and thrive in the low-carbon transition, creating the modern manufacturing economy of the future. We look forward to seeing it go from strength-to-strength over the years to come.”

A jewel in the research centre’s crown is the AMRC Training Centre with the report showing that since opening in 2013, more than 1,700 apprentices have been trained, working with 400 manufacturing firms. Of those apprentices, 80% live in South Yorkshire, demonstrating the important contribution the AMRC makes to upskilling local residents and ensuring local businesses have access to a pipeline of skilled workers.

“In addition, the centre helps to support improved social mobility and inclusion, with 50% of all learners from South Yorkshire living in areas of high deprivation during their apprenticeship,” the report states.

It also notes how the AMRC unlocks innovation activity ‘that could not otherwise take place’ according to its industrial partners and adds value by de-risking innovation; improving the leverage of R&D expenditure; providing access to dedicated R&D space and an unrivalled breadth of industrial expertise; and accelerating the commercialisation of research.

“The AMRC’s profile and reputation positions it as a signature asset for South Yorkshire, supporting the area’s efforts to attract inward investment from advanced manufacturers. This, in turn, has helped to create high value, high productivity jobs in the local economy,” says the report.

“The benefits of locating close to the R&D, innovation and training capabilities offered by the AMRC have attracted a cluster of advanced manufacturing occupiers to the Advanced Manufacturing Park in Rotherham, and the neighbouring Sheffield Business Park. This includes globally significant businesses with strong ties to the AMRC including Boeing, McLaren and Rolls Royce.

“In total, it is estimated that £260m of investment has been attracted across both sites - at least in part - by the presence of the AMRC, resulting in the creation of 600 jobs.”

AMRC CEO, Steve Foxley, said: “It is fantastic to see the impact the AMRC has had over the last two decades in black and white. This Economic Impact Analysis perfectly demonstrates our strengths: driving national innovation, magnetising investment into South Yorkshire and creating a pipeline of manufacturing talent.

“However, the report similarly highlights where we must improve and that is in moving the productivity dial for manufacturers in the regions in which we operate. If we are to maintain our impact we must commit to helping companies on our doorstep improve their processes, upskill their workforces and cut their carbon footprint.

“We should see this Economic Impact Analysis report as a hinge point for the AMRC: it confirms how well we have done in the past and illustrates how we can do even better in the future. We have a great story to tell, but we can raise our game.”

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News: Research firm in Rotherham relocation

A group of life science companies have consolidated their brands onto one site in Rotherham so that they can continue to expand.

A number of similar firms under the Calibre Scientific portfolio now operate from the R-evolution Phase 3 scheme at the world-renowned Advanced Manufacturing Park (AMP) in Rotherham.

Founded in 2013 and headquartered in Los Angeles, USA, Calibre Scientific is a diversified global developer, manufacturer and distributor of consumable products in the life sciences and diagnostics markets. The business has continually expanded through a combination of organic growth and acquisitions, and today has a broad portfolio of more than 3,000 products, which it sells into over 100 countries worldwide.

BioServUK, Molecular Dimensions, and Protein Ark—from haved moved onto the AMP from The Innovation Centre, Sheffield.

BioservUK is an expert in the processing of antibodies and made a research and technology contribution towards Covid-19 testing with PCR and Rapid Antigen kits.

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Situated alongside other market leaders, the customised facility includes hi-tech laboratories for research, development, and product manufacture, efficiently designed warehouse space, and innovative employee workspaces to foster collaboration and communication.

Confirming the move, Calibre Scientific said that the updated facility will bring significant growth and expansion opportunities, ensuring Calibre Scientific remains at the forefront of business operations and scientific excellence in the UK.

Andy Wright, General Manager, Calibre Scientific UK, said: "Relocation to the Advanced Manufacturing Park is the next exciting chapter in the ongoing expansion and evolution of Calibre Scientific within the UK. It allows us to continue our mission of creating a better tomorrow by solving life science challenges, today."

The 2020 planning application that facilitated the move said that the company was seeking to have all employees in one building and want to double their staff from 23 employees to 43 employees in the next three years (by 2023).

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News: Xeros signs global licensing agreement

Xeros Technology Group plc has signed a licensing agreement for its XFilter filtration technology with a world leading manufacturer of components for the appliance industry.

Based on the Advanced Manufacturing Park (AMP) in Rotherham, Xeros is a Leeds University spin-out that has moved to "IP-rich, capital-light" business model with water saving and filtration technologies with multiple commercial applications.

The AIM-listed firm has signed an agreement with Hanning Elektro-Werke Gmbh & Co.KG. which is based in Germany and makes pumps and motors for some of the world's largest domestic washing machine manufacturers.

Hanning components are incorporated in the washing machines of some of the world's leading brands and the agreement is described as transformational for Xeros. It has the potential to deliver significant revenues from late 2023 onwards.

Under the terms of the 10-year, non-exclusive agreement, Hanning will manufacture and sell filters incorporating Xeros' proprietary XFilter technology. This will enable washing machine manufacturers to provide consumers with the ability to capture and easily and safely dispose of over 90% of microfibres, including microplastics, released during laundry cycles. The filters are built into the washing machine and are designed to last the life of a machine.

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Hanning is establishing a production line to meet demand from their customers ahead of new legislation in France requiring the fitting of microfibre filters in all domestic washing machines by 1 January 2025. Similar legislation is in development in the UK. Xeros is already working alongside Hanning on the integration of XFilter within the washing machines of a number of their existing customers.

Under the terms of the agreement Xeros will receive a royalty per filter device sold by Hanning. The royalty amount is commercially sensitive, but Xeros can confirm that the commercial terms of the agreement are in line with the Board's expectations and, as previously communicated, Xeros expects to begin receiving royalty revenues from Hanning in late 2023.

In addition, Xeros continues to make progress under the XFilter development agreement previously announced with a large, Asian-based washing machine OEM and a highly respected testing institute for the textile industry recently accredited Xeros' filtration device with the highest level of performance, capturing over 99% of microplastics.

Klaas de Boer, Chairman of Xeros, said: "The ambition we have been working towards is for Xeros' XFilter technology to establish the de facto standard for legislators and to be the device of choice for all washing machine manufacturers. Our solution is designed to be the most efficient, most reliable, most durable and the easiest to use. This agreement with Hanning is testament to the fact that our solution achieves these objectives. Hanning's customers are now working with us and Hanning for incorporation into their machines.

"Doing so enables them to meet the legislation in France with the expectation that filtration will be mandated across the EU and in the UK.

"Through their adoption of this technology, the washing machine industry will radically reduce the largest source of primary microplastic pollution which is from washing our clothes at home."

The deal is much-needed. Xeros' board said earler in the year that it was actively evaluating several funding options to secure investment as it no longer believed that it was likely to reach month on month EBITDA profitability and cash breakeven in the first quarter of 2023, as previously guided. The Board now expects this to be reached in 2024.

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News: US Air Force fly into the AMRC

The United States Air Force (USAF) has been shown how world-leading technologies and techniques pioneered in South Yorkshire could reshape its day-to-day operations.

A delegation from RAF Lakenheath, home to the 48th Fighter Wing, recently visited the University of Sheffield Advanced Manufacturing Research Centre (AMRC) facilities in Rotherham and Sheffield to understand how digital technologies, composite materials and advanced machining could be integrated into the USAF’s maintenance, repair and overhaul (MRO) processes.

Last year, the AMRC worked with RAF Leeming, home to the RAF’s innovation hub RAF eXperimental (RAFX), to demonstrate how Industry 4.0 digital technologies could transform how it operates and trains its workforce.

Sgt Joseph Slaughter, fabrication flight superintendent in the 48th Equipment Maintenance Squadron, based at RAF Lakenheath, said: “The visit to the AMRC was organised to explore manufacturing capabilities of industry partners and find opportunities for collaboration outside of maintenance and the wing.

“The 48th Equipment Maintenance Squadron (EMS) stood up the Advanced Manufacturing Working Group (AMWG) to identify opportunities to pool collective resources - such as 3D printing and other advanced manufacturing capabilities - to create and manufacture tools, parts, and items for non-aviation equipment and aviation components.

“The 48th EMS has identified this opportunity due to increased supply system shortfalls concurrent with the ageing support equipment and aircraft fleet.”

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At the AMRC’s flagship Factory 2050 facility, which is on the site of the former Sheffield airport, the group was shown augmented reality (AR) and virtual reality (VR) headsets, discrete event simulation software, smart benches, and other digital technologies. At the nearby Factory of the Future in Rotherham, there were demonstrations of the AMRC’s capabilities in advanced machining and the latest composite manufacturing processes.

Recommended reading: Rotherham’s Digital Transformation: Verified Progress in Local Business and Community Support

Jonathan Bray, the AMRC’s senior sector engagement manager for defence and space, said: “It was great to show the USAF around our facilities and explain how cutting-edge technologies can be applied to its operations.

“There is real capacity for us to enhance the way RAF Lakenheath operates by transferring the same innovations that have driven step changes in the aerospace and automotive sectors into the USAF’s processes. There is so much we can achieve together in terms of safety, productivity and sustainability, and I look forward to having more discussions in the future.”

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News: AMRC partners on £1.25m advance wind turbine blade production project

The University of Sheffield Advanced Manufacturing Research Centre (AMRC) is working alongside the University of Hull on a £1.25m project to help Siemens Gamesa tackle a key challenge in the construction of offshore wind turbine blades.

Turbine blades are made using a resin which is injected into a complex mould. However, due to the length of wind turbine blades – currently over 80m and getting bigger – it can be difficult to know whether resin has dispersed evenly through the blade. If resin is not sufficiently dispersed, the blade cannot be installed and the cost implications can be substantial.

A team at the University of Hull are now working with Siemens Gamesa, with support from the AMRC Composite Centre, to address this challenge using fibre-optic sensors embedded along the length of the blade.

If successful, it could have significant cost and efficiency benefits for the offshore wind sector.

Based on the Advanced Manufacturing Park (AMP) in Rotherham, the AMRC has a £4.5m state-of-the-art centre supporting the development of advanced composite materials inside the Factory of the Future. The centre works with complex hybrid components and systems, which require manufacturing expertise in both composite and metallic structures.

Professor Jim Gilbert, Professor of Engineering at the University of Hull, said: “We are delighted to have secured this significant new funding, which will enable the continuation of a successful partnership with Siemens Gamesa.

“As the offshore wind energy sector continues to accelerate, finding solutions to challenges such as this will be essential to ensure the UK can meet its ambitious net zero targets. This project builds on the University of Hull’s reputation as an expert in low-carbon energy, technology and sustainability, and also as a key stakeholder in the Humber region.”

Fibre-optic sensors installed along the length of the turbine blade will make it possible to know what is happening inside the mould as resin is injected - something which is very difficult using conventional sensors. The sensors will be able to monitor the temperature of the resin, how it is flowing along the blade, and whether it is curing at the rate it is expected to.

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Dr Clara Frias, Head of the AMRC Composite Centre, said: “If the UK is to achieve its goal of reaching net zero by 2050, we will need to harness the renewable energy sources at our disposal in the most efficient and productive way possible. Embedding fibre-optic sensors along the length of the turbine blade will give us valuable data, from which we can fully understand the wind turbine blade production process and how to improve it.

“Through this project, the AMRC, University of Hull and Siemens Gamesa can together boost offshore wind production, and ensure offshore renewables are central to the UK’s future energy mix.”

With a total research value of £1.25m, £1m of funding has been provided by the Engineering and Physical Sciences Research Council (EPSRC) for the project which will be led by the University of Hull and supported by the University of Sheffield AMRC and Siemens Gamesa Renewable Energy in the UK and Denmark.

It is a continuation of a successful wider project called Prosperity Partnership – which also brings in Durham University and Ørsted.

Professor Gilbert added: “This project builds on the substantial investment the university has made in Aura, cements the relationship with a key industry partner and establishes a new link with the AMRC in Sheffield.

“Collaboration, which is a key part of Aura’s ethos, is fundamental to the success of this bid: it brings people together across the University of Hull but also strengthens the long-term relationships developed with industry and academic partners.”

One of the reasons fibre-optic sensors are so important is they must be able to withstand the lightning strikes and storms offshore wind turbines encounter while operational.

The project - titled ‘Heterogeneous Fibre Optic Sensor Arrays to Monitor Composite Manufacture’ - is led by Professor James Gilbert of the Department of Engineering and Aura, along with Dr Howard Snelling in Physics and Mathematics and Dr Rob Dorrell in the Energy and Environment Institute. Dr Clara Frias and Dr Kevin Kerrigan, senior technical fellow in the AMRC Composite Centre, will be Co-Principal Investigators from the University of Sheffield AMRC, part of the High Value Manufacturing Catapult.

The work will extend research started as part of the £7.6m EPSRC/industry funded Prosperity Partnership: A New Partnership in Offshore Wind and will apply the approach to improve the quality of complex composite structures such as wind turbine blades.

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News: Metalysis continue to aid hunt for oxygen on the Moon

Rotherham-based tech firm, Metalysis, is taking part in more out of this world research projects.

The Advanced Manufacturing Park (AMP) company holds the worldwide exploitation rights to the FCC Cambridge process which sees specialist powder metals created in a simple, cost effective process with significant environmental benefits. It is commercialising the technology to produce titanium, tantalum, and related high value alloys.

Selected by the European Space Agency (ESA), Thales Alenia Space is leading a €1m study to develop a demonstration payload to extract oxygen from Moon rock to sustain human activities on the Lunar surface.

For a sustainable habitation on the Moon, humans will need to utilise resources that they find on the Moon rather than transport these resources from Earth; one of these resources is oxygen.

Last year Metalysis successfully extracted oxygen from replicated moonrock (lunar regolith) which predominantly contains aluminium, silicon, and oxygen, as part of the research programme. The metal powder by-product collected during the process is also generating huge interest.

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Andrew Stanniland, CEO of Thales Alenia Space in the UK, said: "This contract award is incredibly exciting. The adaption of processes and tools to the space environment, many of which we take for granted on Earth, will be critical in many areas of our future. I am proud that our dedicated teams will be leading this study together with our valued partners AVS, Metalysis, Open University and Redwire Space Europe to solve the complex challenge of creating oxygen to sustain life on the lunar surface."

Metalysis has also been named in a project backed with £218,000 from the UK Space Agency.

Called "Developing In Situ Resource Utilisation Production Technology (DISRUPT)," the project will establish an end-to-end demonstration capability in the UK which would contribute significantly to the de-risking of technology used for In Situ Resource Utilisation (ISRU). This end-to-end demonstration capability would allow many of the uncertainties present in the process chain to be understood and characterised; especially the effect of the regolith (Moon soil) collection and pre-processing of the feedstock for the Metalysis-FFC process reactor. This activity will be conducted in partnership with Metalysis, AVS, URA Thrusters and the Open University.

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