News: Dinnington design firm expands 3D print service

A Rotherham product design company has raised £500,000 from NPIF – Mercia Equity Finance, which is managed by Mercia and part of the Northern Powerhouse Investment Fund (NPIF), to help expand its 3D print production service and target new markets.

AME Group is based at Dinnington and designs products for many leading consumer brands including Jaguar, Vax, Hornby Railways and Harris Brushes. Its 3D print service was initially introduced to produce prototypes. However, following an initial £750,000 investment from NPIF last year, the company invested in new equipment and is now offering a low-volume production service with rapid turnaround times.

It currently produces components for clients in the aerospace, defence and the luxury yacht market. The latest funding will enable it to broaden its product range and target new sectors, as well as meet the growing demand for its design services. AME Group was founded in 1998 by Ian Jones, who is Finance Director. It currently employs 28 staff and expects to create around ten new jobs in the next two years.

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Rich Proctor, the company’s CEO, said: “3D printing is catching on quickly as it enables companies to shorten lead times by manufacturing small batches in the UK, test new product ideas and respond rapidly to market trends.

“Many businesses are also looking to redesign their existing products to reduce cost or make them more sustainable. And overall, there is a greater appreciation of products and their ability to differentiate a company in the market, rather than relying solely on digital assets.”

Maurice Disasi of Mercia added: “AME Group is recognised as one of the leading product design specialists in the UK and it is now establishing itself as a specialist in 3D print production. This latest funding will enable it to meet growing demand for its services.”

Sean Hutchinson at the British Business Bank said: “We are pleased that the Northern Powerhouse Investment Fund is continuing to support high-growth businesses in the North, providing vital funding to aid companies like AME Group to meet market demands, and innovate their services. The development of AME Group’s production and their plans for product expansion is testament to the role NPIF plays in creating a more prosperous regional economy, through the businesses its funds invest into.”

The Northern Powerhouse Investment Fund project is supported financially by the European Union using funding from the European Regional Development Fund (ERDF) as part of the European Structural and Investment Funds Growth Programme 2014-2020 and the European Investment Bank.

AME Group website
NPIF website

Images: Mercia

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News: AME Group's "gamechanging" work in medical sector

AME Group, a leading prototype manufacturer that is based in Dinnington, Rotherham, has highlighted the role of good design in healthcare - an industry driven by innovation.

The growing company combines a team of creative designers and technical designers who work on new products and create high-specification prototypes using 3D printing technology for customers including Dyson, GlaxoSmithKline, Hornby, Morphy Richards and Unilever.

The business was founded in 1997 after managing director Ian Jones - a mechanical engineering graduate, who cut his teeth working at the Selby coalfield - was made redundant from his job with British Coal. It is now based on the site of the former Dinnington Colliery.

In the company's "Gamechanger" publication, Tim Stern, design manager at AME Group, said: "In order to relieve the strain on hospitals and doctors' surgeries, patients will be increasingly relied on to use remote diagnostic and monitoring devices. This raises some big issues for the designers of medical devices.

"The increased reliance on patients to use equipment means that products will need to have an intuitive design that is easy to use. Devices will also need to deliver quick results that are easy to interpret.

"As the medical space becomes more crowded, hardware and user interface design will become key differentiators, with buyers more likely to factor user experience into their purchasing decisions."

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One such product that AME group has worked on is MicroBioSensor (pictured, below) - supporting the University of Manchester spinout company to develop potential applications for its detection chemistries into commercially viable products.

A number of prototypes were developed to address the problem of medical device use actually increasing risks of patients contracting an infection. The outcome is an early warning device that, with a simple change of colour, identifies an escalating infection and the appropriate treatment. The device fights multi-drug resistance by improving the management of effective antibiotic drugs, facilitating care away from hospitals and reducing pressure on the healthcare system.

Another product where the focus is on the user is RapidRhythm (pictured, top), which could soon reduce heart screening times by over 80%.

User-centric design from AME Group has helped to develop a wireless handheld device that allows heart patients to be screened in just 90 seconds. The current screening method is an electrocardiogram (ECG) test, a procedure that takes up to 20 minutes.

RapidRhythm requires less training than traditional ECG and provides fewer failed readings.

The product was engineered in 3D CAD, with a number of test prototypes created using AME's in-house facilities. This enabled engineers to assess the design, highlight issues and minimise the risk and potential costs of resolving them at a later date.

AME's low volume production facilities will be used to manufacture a small quantity of the devices, which will be used to validate the Rapid Rhythm product in the field.

AME Group website

Images: AME Group

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News: AME Group looks ahead as it celebrates 20 years in business

AME Group, a leading prototype manufacturer that is based in Dinnington, is looking to develop its product design business as it celebrates 20 years since starting up in a concrete outbuilding at founder, Ian Jones' Rotherham home.

The innovative company combines a team of creative designers and technical designers who work on new products and create high-specification prototypes using 3D printing technology for customers including Dyson, GlaxoSmithKline, Hornby, Morphy Richards and Unilever.

The business was founded in 1997 after managing director Ian Jones - a mechanical engineering graduate, who cut his teeth working at the Selby coalfield - was made redundant from his job with British Coal.

Seeing the potential of 3D printing technology for prototyping, Ian drew up a business plan and raised enough money to buy an early print machine.

"When it arrived, it was absolutely rubbish," Jones recalls. "I am not sure it managed to produce one successful part. It was very slow and, in retrospect, had been launched too early. The positive side was that it opened a lot of doors to prospective clients and ultimately led me to discover other more reliable technologies and partners that were already using them."

One of AME Group's first clients was Stanley Tools, and the success of the partnership resulted in AME investing in new technology and premises.

Ian's long-standing friend and MBA qualified manager Paul Howell joined the business as joint managing director and co-owner and the Dinnington headquarters were built on the site of a former South Yorkshire colliery in 2006. The premises house a growing design team and state-of-the-art prototyping workshop.

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Jones (pictured, right) said of the growing business: "We had become highly skilled at prototyping but we knew there was an opportunity to move upstream and get closer to our clients by using our expertise in product design. Securing work from globally renowned manufacturers such as Procter & Gamble showed that our approach was right."

Showing that the business is "not just about drawing pretty pictures," several innovative start-up businesses have been incubated at the AME Group who helped them to turn their ideas into commercially successful and market leading products. One example being the Identicom product, now the UK's most widely deployed dedicated lone worker device, that saw SoloProtect (formerly Connexion2) grow from Dinnington to new purpose built premises in Sheffield following a multimillion pound takeover.

AME employs 22 people and has a turnover of £1.5m. Having started out as a prototyping specialist, the future for AME Group is focused on developing its product design business. "We want to increase our design revenues over the next three to five years," says Ian "and continue to deliver the very best in innovative product design services, developing market leading products solutions for our clients, helping their businesses experience commercial success."

The quality of the work produced was recently recognised with a prestigious Red Dot product design award for its work on JigTech Pro, an innovative device that enables door handles to be fitted in minutes.

Jones concluded: "I'm proud of the fact that we have traded very successfully throughout the ups and downs of a changing economy but, most of all, I'm proud of the way the business has developed its staff. Several people have been with us for more than 15 years. Paul and I are not micro managers. We give freedom to the team to grow.

“We are not a massive company but we have a highly credible and experienced team that inspires confidence from a diverse portfolio of clients that see us as a strategic product development partner."

AME Group website

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News: Medical AMRC test the boundaries of new 3D printer

Engineers from the University of Sheffield Medical Advanced Manufacturing Research Centre (ARMC) have used a new 3D printer to create a model of the delicate structure deep inside the ear called the labyrinth.

Based in the centre's Design, Prototyping & Testing Centre on the Advanced Manufacturing Park (AMP) in Rotherham, the Medical AMRC sits alongside the current AMRC, a world class centre for advanced machining and materials research, and has access to all the current resources but with a dedicated team which specifically focuses on the medical technologies sector.

Glen Watson, an ENT Surgeon at the Royal Hallamshire Hospital in Sheffield needed a more accurate model to help him demonstrate benign paroxysmal positional vertigo (BPPV) to patients and educate them about possible treatments.

After a chance meeting with an AMRC engineer, it was decided that a new piece of 3D printing equipment acquired by the AMRC could be used to design and build a model for Glen that would fulfil his requirements.

BPPV is caused by displaced calcium carbonate crystals from one part of the balance organ into another part (the semi-circular canals) that stabilise vision on head movement. As a result of crystal debris floating around in the canals, confusing signals are sent to the brain causing brief but intense spinning sensations on looking up, down and often turning over in bed.

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A simple but effective treatment is to recognise the condition and perform a liberating or repositioning manoeuvre, to move the crystals into a part of the balance organ where they cause no further problem; akin to completing a ball-in-a-maze puzzle.

Glen Watson said: "Most of the models of the labyrinth concentrated on the cochlea with limited, or no models demonstrating the disease process of BPPV in the semi-circular canals. This made it difficult to explain BPPV to patients and explain how it is treated.

"When I talked about "crystals" that were loose in their head I often received odd looks! The model that Medical ARMC has produced on their 3D printer will enable patients to visualise what is happening and understand the disease in a simple fashion."

The Medical AMRC decided to test the limits of their new FormLabs Form2 3D resin printer and offer to design and print a model of the labyrinth, demonstrating the semi-circular canals, free of charge as a test piece for their new capabilities. The model would be complete with movable crystals that could be seen from the outside.

Valdis Krumins, project engineer at the AMRC, said: "The project for Glen helped us commission and test our new Form2 3D printer. It was a useful learning process stretching the capabilities, and using the whole working envelope of the machine.

"Laser printing in resin allows us to print in translucent material and in high-definition with small intricate details compared to standard fused deposition modelling processes."

Medical AMRC website

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News: New wings at the AMRC

Engineers at the University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing in Rotherham continue to showcase their capabilities in prototyping and design by further developing an Unmanned Aerial Vehicle (UAV).

Based on the Advanced Manufacturing Park (AMP) in Rotherham, the AMRC is a world leading model partnership between industry and academia that focuses on advanced machining and materials research for aerospace and other high-value manufacturing sectors. It employs around 200 highly qualified researchers and engineers from around the globe, who have worked on manufacturing challenges for likes of Airbus, Boeing and GKN Aerospace.

Small fixed-wing remote-controlled aircraft – often known as unmanned aerial vehicles (UAVs) – have a host of applications such as aerial surveys, photography and environmental monitoring. A team at the centre's Design & Prototyping Group set themselves the challenge of proving that a viable UAV could be made using relatively simple additive manufacturing technologies.

Making the glider involved developing new techniques that rapidly reduced the time, the amount of materials and the cost of manufacturing components using 3D printing technology. Creating the latest version of the UAV, which now includes electric-powered, ducted fan engines, has involved further advances in making functional parts using Rapid Manufacturing (RM) technology.

Members of the team recently returned from Salt Lake City, after being invited to deliver a presentation on the UAV project to an aerospace manufacturing conference organised by SAE, the global association for aerospace, automotive and commercial vehicle industries engineers and technical experts.

New manufacturing techniques were developed for producing carbon fibre components and making component jigs, fixtures and moulds, as well as parts of the UAV's airframe, by Fused Deposition Modelling (FDM).

They also improved pitch control by creating a moveable "Duck Tail" that uses concepts similar to those recently used in Formula One racing to harness the air leaving the UAV’s engines for aerodynamic effect.

Last, but not least, they designed a launch catapult, including parts made by RM technology, which can propel the UAV into the air with an acceleration up to three times that of gravity and a speed of just under 30 miles an hour.

Having developed a UAV, capable of cruising at around 45 miles an hour, the team’s next challenge will be to replace the electric ducted fans with miniature gas turbine engines and double the UAV’s wingspan to three metres.

The team is also looking at using novel ways of controlling flight to replace conventional methods and developing structural batteries – reducing weight by using parts of the UAV's structure to store the power it uses to fly.

Dr Garth Nicholson, senior design engineer at the AMRC (pictured, far right) said: "The project was a success on all levels, from team building, experience gained in structural and systems design and design for manufacture through to testing and validation of Computational Fluid Dynamics.

"The aircraft was developed using both an incremental design philosophy, as well as trialling experimental manufacturing techniques in carbon fibre production."

AMRC website

Images: AMRC

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News: All eyes on Picsima

Fripp Design and Research, one of the UK's leading product design, research and business consultancies, is showcasing its advancements in 3D printing at a leading trade show this week.

Based at the Advanced Manufacturing Park (AMP) in Rotherham, Fripp are experts in all areas of product design and industrial design with customers ranging from blue chip companies, to UK leading universities, to individual inventors and entrepreneurs. It also develops its own own intellectual property in areas ranging from DIY to healthcare.

The firm is developing a 3D printer that prints in full colour silicone, a world's first, that will revolutionise the rapid manufacture of soft tissue prosthetics, including "new" ears, noses and eyes.

The advancements are being showcased at the UK's leading show on 3D printing and additive manufacturing - TCT + Personalize, where Fripp will display the system it calls Picsima, and launch its 3D silicone printing bureau service.

Using 3D printing technology in the medical sector dramatically reduces the time and cost of manufacture without need for invasive procedures. A patient can quickly obtain necessary replacements without having to revisit the clinic. Fripp co-own a number of patents in the manufacture of 3D printed medical devices.

3D printing often creates solid objects by building them up in very fine plastic layers. Fripp has been producing prosthetics by printing with starch powder to form a model which is then vacuum-formed with medical grade silicone. Now it is close to launching a system that prints direct with silicone, in full colour.

Tom Fripp, director at Fripp Design and Research, said: "We have spent the past 18 months developing our method for 3D printing silicone.

"Because we are using commercially available silicones, we are creating 3D printed parts with the material characteristics provided by the source manufacture, but without the need to create a mould and then vacuum cast; we simply 3D Print them. That means we can make parts very soft, extremely durable and capable of being steralised if required and we take out an entire process compared to other polymer based 3D Printing technologies; who needs to cast silicone anymore?"

The research has been backed by a grant from the Technology Strategy Board, the concept is being proven, and Fripp is working with commercial partners for further development of the technology through to a commercially available system.

Fripp Design website

Images: Fripp Design and Research

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News: Fripp go further in 3D

Fripp Design and Research, one of the UK's leading product design, research and business consultancies, is close to launching a world first - a 3D printer that prints in full colour silicone.

Based at the Advanced Manufacturing Park (AMP) in Rotherham, Fripp are experts in all areas of product design and industrial design with customers ranging from blue chip companies, to UK leading universities, to individual inventors and entrepreneurs. It also develops its own own intellectual property in areas ranging from DIY to healthcare.

The experts, Tom Fripp and Steve Roberts, were at the 3D Printshow in London recently (pictured below) to showcase the firm's advancements in the rapid manufacture of soft tissue prosthetics, including "new" ears, noses and eyes.

Working with the University of Sheffield and with funding from the Wellcome Trust, Fripp has developed a system to fabricate soft tissue prostheses for patients suffering from facial deformities as a result of disease or serious accidents. It captures 2D colour and 3D spatial data independently to match the patient to the prostheses.

Using 3D printing technology dramatically reduces the time and cost of manufacture without need for invasive procedures. A patient can quickly obtain necessary replacements without having to revisit the clinic. Fripp co-own a number of patents in the manufacture of 3D printed medical devices.

3D printing often creates solid objects by building them up in very fine plastic layers. Fripp has been producing prosthetics by printing with starch powder to form a model which is then vacuum-formed with medical grade silicone. Now it is close to launching a system that prints direct with silicone.

The research has been backed by a grant from the Technology Strategy Board, the concept is being proven, and Fripp is working with commercial partners for further development of the technology through to a commercially available system.

Outlining the potential benefits of the project, called Picsima, Tom Fripp, managing director of Fripp Design and Research (pictured, right), said: "The benefits are numerous and include bringing the advantages of 3D printing to an even broader range of consumers.

"Components that would have to be assembled or bonded may now be manufactured as one part and true colour elastomer parts can be manufactured in high performance, medical grade materials.

"Applications as broad as medical, industrial, consumer products and automotive stand to benefit from this technology."

Fripp Design and Research website

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News: Fripp Design and Research open new office in London

Fripp Design and Research, one of the UK's leading product design, research and business consultancies, has opened a new office at Chiswick Park in Chiswick, London.

Based at the Advanced Manufacturing Park in Rotherham, Fripp are experts in all areas of product design and industrial design with customers ranging from blue chip companies, to UK leading universities, to individual inventors and entrepreneurs. It also develops its own own intellectual property in areas ranging from DIY to healthcare.

Tom Fripp, managing director at Fripp Design and Research, said: "We have established an enviable reputation for providing our clients with highly innovative, creative but pragmatic industrial and product design within the Sheffield City Region. That reputation has spread nationwide and we are getting more interest in our design capabilities from London based companies."

Fripp Design and Research realised that, to better support and service their clients in the south of England, they needed to be able to provide customers with easier access.

Fripp added: "We understand how valuable time is to our clients. Expecting clients to spend the entire day coming to see us in Sheffield just did not make sense to us. We wanted to demonstrate our support to our clients by establishing a local office; making it easier for them to work with us to achieve their design objectives. We wanted a location which was easy for clients to get to us from Central London, as well as being commutable for those who are located further afield. Not only is Chiswick Park convenient for our clients, the environment is great for creative design too."

The company was involved in the design of the Comic Relief "Honkus" Red Nose and have appeared on Channel5's, the Gadget Show. Clients also include; Fellowes, Rolls Royce, Proware Kitchen, Sagentia Group, Nestlé and The Wellcome Trust.

Fripp Design and Research website

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News: Maplin brings 3D printing to the High Street

Rotherham-based electronics retailer, Maplin, has become the first major high-street retailer in the UK to sell 3D printers.

Manvers-based Maplin sells a range of 15,000 products to tech-savvy hobbyists as well as general consumers. The company's website attracts over 170,000 visitors every day and they operate a network of over 200 retail outlets throughout the UK and Ireland. They employ 2,500 staff.

The Velleman K8200 3D printer kit will go on sale in selected stores this week priced at £699.99

3D printing creates solid objects by building them up in very fine plastic layers. The first step is to create the 3D object design by using digital software on a computer. This design is transmitted to the 3D printer which begins to build up the design in plastic.

The printer melts plastic filament, then draws with it in a very fine layer. It then builds another layer of plastic on top, then another, and another, building a design in levels from the bottom up until you have a plastic object ready to hold and use.

From prototypes for new inventions to intricate models; 3D printing opens up a whole world of possibilities for creating replacement parts, bespoke toys or objets d'art. The only limit is the size of the printable area which is 20cm³.

The technique is being pioneering in rapid prototyping by the likes of Materialise and Fripp Design and Research on the Advanced Manufacturing Park in Rotherham.

Oliver Meakin, commercial director at Maplin, said: "We have been excited about 3D printing technology for a long time, as its principles of innovation and creation sit perfectly with what Maplin has been doing for over 40 years. Until now, the cost of 3D printers limited their use to the professional market. However, the Velleman K8200 kit has enabled us to introduce 3D printing to the mass market.

"We selected this model primarily because it offers high performance printing at an affordable price, making it accessible to our customers. In addition, it requires assembly before use, which fits with the "build it yourself" ethos so central to Maplin's heritage. Part of the enjoyment lies in putting the kit together, so users are not just investing in a great product, but an experience too.

"Our in-store Maplineers are technical experts in this field and therefore we are in a great position to assist our customers in understanding this product, which for many will be completely new. This is only a first step for Maplin into the world of 3D printing and we look forward to developing this category further in the future."

Maplin now has a turnover of more than £200m, a world away from the early days in Essex when founders, Roger Allen and Doug Simmons, remained in their full-time jobs for two years, and the company didn't make a profit.

In 2008 they moved to a 220,000 sq ft state of the art distribution centre and head office at Manvers in Rotherham.

Maplin website

Images: Maplin

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News: Fripp Design up for 3D4D challenge

Experts from Fripp Design and Research, based at the Advanced Manufacturing Park in Rotherham, have reached the final of an industry competition that aims to develop 3D printing technologies to deliver real social benefits in the developing world.

The 3D4D challenge recognises a number of projects harnessing the benefits of 3D printing and Fripp has been working on a project for the manufacturer of soft tissue prostheses.

Working with the University of Sheffield and with funding from the Wellcome Trust, Fripp has developed a system to fabricate soft tissue prostheses for patients suffering from facial deformities as a result of disease or serious accidents.

Using 3D printing technology dramatically reduces the time and cost of manufacture without need for invasive procedures. A patient can quickly obtain necessary replacements without having to revisit the clinic.

Fripp Design's focus to date has been to develop a commercial offer for the UK National Health Service. With a top prize of $100,000 going to the winner, the 3D4D challenge provides an opportunity to develop a low cost system for the developing world so that people in local communities can manufacture soft tissue prostheses for themselves.

Tom Fripp of Fripp Design and Research, said:"We have developed the technology to be able to 3D print soft tissue prostheses but are now struggling to bring it to market in the UK because of the many issues surrounding ethical approval, which involve a lot of paper work.

"The UK does not have the same problem to solve [as the developing world] as there is no shortage of prosthetic technicians and NHS funding is often available. Our technology cannot quite match the quality of their work but in poorer countries such technicians are both expensive and scarce."

This is just one project that the experts are working on. Through a separate part of the company called Applied Industrial Design, technology and technical expertise is being applied to design solutions to address other healthcare problems.

Tom added: "It has taken four or five years to develop the technology for this project. As a business, we started out as an industrial design company and although we were aware of 3D printing, it was just a tool. We now develop products and processes for medical or healthcare providers."

The winners of the 3D4D challenge will be announced at the 3D Printshow in London on Friday October 19.

Fripp Design website

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News: Materialise work on life saving product

Engineers from Materialise UK on the Advanced Manufacturing Park (AMP) in Rotherham have helped to bring to reality a concept that will help to make sterile drinking water available to some of the world's most remote locations.

LIFESAVER systems, a British company founded by Michael Pritchard in 2007, produced the first water bottle to remove all bacteria, viruses, cysts, parasites, fungi and all other microbiological waterborne pathogens without the aid of any foul tasting chemicals.

With around six thousand LIFESAVER Ultra Filtration jerrycans already distributed in the Malaysian Peninsular and Sarawak, feedback came in that a larger community-centered system would be of great benefit to the region.

So began the LIFESAVER M1 project, a joint venture between LIFESAVER systems Ltd. and H20 Saver SDN BHD. Then when, at short notice, a visual prototype was required for LIFESAVER M1's official launch in Malaysia, Materialise helped Michael make it happen. There was less than a month to get a visual prototype of the LIFESAVER M1 3D printed, assembled, finished, and ready for the launch event in Malaysia.

The Materialise UK team based at the AMP worked with Michael and his colleagues to ensure that changes were made to the original CAD files, to make certain that not only could the parts be built on Materialise's Mammoth Machines in Belgium, the only machines large enough to take a project such as this, but that after production the parts could also be quickly and accurately assembled.

The manufactured parts were re-enforced during the production process, before being sent to a team of finishers who completed the project in time for shipping to Malaysia.

The event included a visit by UK Prime Minister, David Cameron, and the reception for the LIFESAVER M1 has been so positive that full production of the units should commence in late summer 2012.

When it is up and running, it is estimated that the project will provide up to 2 million litres of sterile drinking water to over 42,000 people in rural Malaysia.

Philip Hudson, managing director of Materialise UK, said: "It was great to be involved in this project and to work with Michael and his team. Michael is really inspirational when you meet him and it's clear that the LIFESAVER products are making a big difference for some of the world's poorest and most isolated communities."

Materialise website

LIFESAVER website

Images: lifesaversystems.com

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News: Materialise technologies showcased at the V&A

Radical advances in digital, laser and new additive manufacturing technologies initiated by Rotherham-based Materialise are to be part of an exhibition at the Victoria & Albert (V&A) Museum in London this month.

"Industrial Revolution 2.0: How the Material World Will Newly Materialise" is taking place as part of the London Design Festival and it will be the first exhibition to solely feature 3D printed pieces.

Renowned New York-based design gallerist and curator Murray Moss has collaborated with industry leader Materialise to bring together a series of unique printed works, using cutting edge laser and digital technologies to build three-dimensional objects.

Moss has commissioned eight designs from the worlds of fashion and furnishings, all sponsored and produced by Materialise. They will be placed throughout the Museum's most important galleries, wittily referencing eight of the Museum's key pieces and spaces.

Murray Moss said: "My aim was to initiate little narratives, some of which I hope will amuse - between certain of the Museum's historical holdings and these futuristic contemporary objects, not only shedding new light on the Museum's collection, but, in the process, demonstrating the wide reach of these new technologies."

Additive Manufacturing allows for the three-dimensional printing of objects; a sophisticated fabrication process once reserved for prototyping but which is quickly becoming ubiquitous and is permeating all areas of the contemporary material world, including fashion and domestic furnishings, as well as transportation, medicine, and architecture.

The Belgian company has their UK operation on the Advanced Manufacturing Park in Rotherham which has the largest capacity of rapid prototyping equipment in Europe. Experts have created an articulated light shade that can be opened or closed like a blooming lotus flower (pictured), a couture fashion dress in 3-D printed nylon and intricately designed tables and chairs, using 3-D printed epoxy resin.

Materialise website

Images: vam.ac.uk

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News: Materialise help to realise Jaguar's C-X75 concept car

Specialists from Materialise UK in Rotherham have worked with Jaguar Land Rover engineers to provide solutions for the unique design challenges associated with the company's revolutionary C-X75 concept car.

Based on the Advanced Manufacturing Park in Rotherham, Materialise UK, has the largest capacity of rapid prototyping equipment in Europe. Their alternative production techniques matched the designer's desire to use organic shapes in the car's interior cabin.

After collaborating with the Jaguar Land Rover teams to gain a full understanding of the component requirements in relation to the rest of the car, the Materialise engineers used their expertise in rapid prototyping processes to develop ideal solutions.

Due to the client requirements, the majority of the parts were produced in ABS plastic using the Materialise suite of Fused Deposition Modelling machines (FDM), which enabled the components to be constructed directly from the supplied 3D computer data. Materialise used its engineering experience and dedicated software to add the required internal strengthening ribs and structures to provide the components with integral strength and durability.

Other components not requiring such a high degree of functionality were produced by stereolithography on Materialise's patented "Mammoth" machines, allowing large components to be manufactured in single pieces. This offered a big advantage as large components of this type traditionally need to be cut and glued, thus compromising on strength and finish.

A further benefit of the techniques recommended by Materialise was the relative speed of the processes, which typically takes around 50% less time than conventional methods. This allowed the Jaguar Land Rover engineers additional time to refine their CAD designs.

Johnathan Andrews, Account Manager of Materialise UK said: "We were delighted to work alongside the Jaguar Land Rover teams to contribute to the next generation of concept vehicles. I hope that the automotive industry sits up and takes note of the forward thinking technologies that the Jaguar Land Rover engineers applied to this car.

"By utilising additive manufacturing technologies they have set the bar to a new level for concept design by being able to create organic forms and have a freedom of creation that was previously limited."

Project C-X75 was conceived to celebrate 75 years of Jaguar and the British marque recently announced that it will go in to production. The C-X75 is a state-of-the-art supercar that will be one of the fastest, low-emission vehicles in the world.

Ian Callum, design director at Jaguar said: "This will be one of the finest looking Jaguar's ever produced. We have to make changes to bring this car to the market, but I know it will retain all the visual impact of the original concept car."

Materialise website
Jaguar website

Images: jaguar.com

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News: Materialise blend organic beauty and modern technology

Materialise UK Ltd has used their expertise in Additive Layered Manufacturing to produce the intricately designed trophies that were presented to the winners of the recent Brit Insurance Design of the Year 2011 awards.

Based on the Advanced Manufacturing Park in Rotherham, Materialise UK, has the largest capacity of rapid prototyping equipment in Europe.

The trophies were a creation of the London-based artist Ross Lovegrove who has worked with Materialise on numerous projects. Ten trophies that blend "organic beauty and modern technology" were manufactured using the selective laser sintering methods.

Philip Hudson, Managing Director of Materialise UK said: "We were pleased to be contacted by Ross (Lovegrove), and are delighted to produce the trophies for such a globally significant design award competition.

"The intricacies and detail of the design gave us a great opportunity to showcase the capabilities of our additive manufacturing processes, and demonstrate that our world-leading technology can allow truly unique one-off pieces and short production runs to be accurately and cost-effectively produced."

The advantages of additive manufacturing have been used by Materialise to develop unique solutions that make a world of difference for its many customers with their prototyping as well as production needs. These customers range from large companies in the automotive, consumer electronics and consumables sectors; to famous hospitals, research institutes and clinicians.

Materialise website

Images: Materialise

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News: Roberts steps down at Fripp Design

After spending five years establishing Fripp Design and Research as one of the top industrial design practices in the UK, Steve Roberts is relinquishing his position as managing director.

From their premises on the Advanced Manufacturing Park in Rotherham, Fripp Design and Research doubled its workforce and its turnover in 2010 and also significantly increased its customer base, adding well-known names such as B&Q, Boots, Balfour Beatty, The Wellcome Trust and Sheffield University to its portfolio.

The company has announced the appointment of Tom Fripp to the position of managing director following from the appointment of Charles Turner, managing director of Sheffield based knife manufacturer Durham Duplex, as non executive chairman in May.

Steve Roberts said: "After five years, working closely with Tom and Sue (Steve's wife), building Fripp Design and Research's reputation and revenues, it is now time to hand over the reigns to the next generation.

"Fripp has some very exciting opportunities in the area of rapid manufacturing which require Tom's expertise to drive the business to the next level."

Steve will be staying on as a non executive director to provide Tom with support and guidance in his new role. "Tom has the unanimous support of all the Shareholders and I wish him well in what is a very exciting time for the business." added Steve.

Fripp Design and Research website

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News: Materialise UK at TCT Live

Experts from Materialise UK Ltd in Rotherham showcased the latest developments in low volume manufacturing and additive manufacturing software technology at the recent TCT Live show.

With a base on the Advanced Manufacturing Park, Materialise is the world leader in rapid prototyping and low volume manufacturing solutions, offering expert services in these areas as well as being a provider of innovative software solutions. Amongst its clients it boasts many leading companies from the aerospace, automotive, medical technology and consumer electronics/ consumables sectors.

Experts demonstrated the latest additive manufacturing software solutions that not only offers customers obvious cost and lead-time advantages, but also provides increased design freedom and the possibility to personalise products aimed at a niche markets.

Its Low Volume Manufacturing Solutions enable production ready components to be manufactured in days, with minimal investment costs. Such solutions are already used in the production of concept cars, patient-customised medical implants and bespoke design products, where the quantity of products required are too small to justify a conventional production mould investment.

Materialise has the innovative technologies to build single piece products up to 2100x680x800mm, allowing large components such as automotive dashboards and bumper assemblies to be cost-effectively produced. The technology was also used earlier this year to produce a full sized replica of King Tut's mummy for an exhibition in New York.

Philip Hudson, Managing Director of Materialise UK said: "The show was very successful, and a great opportunity to show the latest capabilities of our rapid prototyping and low volume manufacturing services, in addition to our additive manufacturing software solutions.

"Techniques and materials have advanced in such a way that they can be used in production environments and allow our manufacturing solutions to rival traditional subtractive production technologies, whilst also offering degrees of customisation unthinkable only a few years ago.

"The technologies have applications across a wide range of industry sectors and the interest in the solutions we received at the show reflects this fact."

Visitors to the Materialise UK Ltd stand were also able to experience the thrills of extreme winter sport with the Skeleton Challenge from fellow AMP company, Bromley Technologies.

The Challenge uses a unique skeleton simulator, combining head mounted 3D technology with a composite sled, manufactured by Materialise, and incorporating sophisticated balance and movement systems. Riders can test their skills on simulations of some of the world's most challenging skeleton bobsleigh tracks, where competing athletes can travel at speeds of up to 90mph, and experience 5Gs in some bends.

Materialise website
Bromley Technologies website

Images: materialise.com

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News: Take the Skeleton Challenge with Materialise UK

Visitors to the Materialise UK Ltd stand at TCT Live 2010 show later this month will be able to experience the thrills of extreme winter sport with Bromley Technologies Skeleton Challenge.

The Challenge uses a unique skeleton simulator, combining head mounted 3D technology with a composite sled, manufactured by Materialise, and incorporating sophisticated balance and movement systems. Riders can test their skills on simulations of some of the world's most challenging skeleton bobsleigh tracks, where competing athletes can travel at speeds of up to 90mph, and experience 5Gs in some bends.

Following strict guidelines the simulator sled pan, supported by Yorkshire Forward's Rapid Additive Manufacturing Programme, was built using additive layered manufacturing technology.

As the simulator is used in the public domain, particularly within schools, the pan needed to withstand up to 100Kg weight load. Following technical discussions with Materialise, Bromley chose to opt for the FDM solution, using a sparse build to keep the weight to a minimum whilst maintaining the mechanical strength. The pan was painted to a high gloss standard to emulate the real pan.

Following the success of the pan, Materialise in collaboration with Bromley Technologies; and other companies at the Advanced Manufacturing Park (AMP) in Rotherham, produced an enhanced aerodynamic technology package in record time for two of Team GB's top skeleton bobsleigh athletes ahead of the Vancouver Winter Olympic Games.

As aerodynamics are relatively easy for competitor teams to copy, the ultimate aerodynamic design was finalised after the last race of the World Cup season leaving a very short turn around time to test the proposed package, analyse the results and make the decision to go ahead with the new designs or not.

The pan was designed, manufactured and delivered within 48 hours by Materialise in the UK and Belgium and the University of Sheffield's Advanced Manufacturing
Research Centre with Boeing (AMRC) used their stat-of-the-art five-axis machine to produce moulds in a matter of days.

Philip Hudson, Managing Director of Materialise UK said: "The fact that additive manufacturing technologies like FDM & stereolithography are being used more frequently in these types of applications is proof that the techniques and materials have improved in such a way that they can be used in production environments.

"The use of additive manufacturing processes does not only offer obvious cost and lead-time advantages, but also provides increased design freedom and the possibility to customise products. By producing only what you need, additive manufacturing offer a clear advantage over traditional subtractive technologies."

Taking place annually, TCT successfully draws together everyone involved in the concept, design, manufacturing and specification functions. TCT Live 2010 takes place on October 19 - 20 at the Ricoh Arena, Coventry.

Materialise website
Bromley Technologies

Images: materialise.com

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News: Sandvik invests in rapid capabilities at Rotherham facility

Recognising the importance of innovation and speed to market as key differentiators for medical device manufacturers, Sandvik has invested in their rapid prototyping and rapid production capabilities at the Sandvik European Centre of Excellence (SECoE) at Beighton Link Business Park in Rotherham.

Sandvik provides a comprehensive range of capabilities, making it possible for original equipment manufacturer (OEMs) to explore designs and trial prototypes quickly and easily as well as manufacture small numbers of specialised or specific products in a short timeframe.

The Rotherham facility has an area dedicated to rapid production and prototyping for the development and manufacture of orthopedic implants, instruments and medical material. It now includes a recently acquired DMLS (direct metal laser sintering) machine, a Thermojet wax printer and an Objet resin printer.

John Reynolds special projects manager at Sandvik said: "Prototyping is an important stage in the creation of a new device, since it provides the opportunity to explore the design and make the necessary adjustments prior to full production.

"Many medical device OEMs may also require very small production runs; this may be because only ten or 20 units of particular large, high value implants are required in a year or development parts are required for inspection and analysis.

"To be competitive and succeed in the long term OEMs need to work with organisations with the experience, skills and capability to support these requirements; our program of investment coupled with our commitment to always deliver tangible commercial benefits to medical device OEMs means we are positioned to support their requests."

In each rapid prototyping project, Sandvik works directly with the OEM's CAD (computer aided design) drawing to find the most suitable rapid prototyping technique.

Using the Thermojet wax printer saves a valuable 17% of the time taken by traditional methods of prototype manufacture. The printer creates a wax pattern for analysis from which cast parts can be manufactured.

The Objet resin printer produces three dimensional patterns and models in polymer materials from layers as small as 16 microns. Production of cast samples takes just 65% of the time taken using traditional methods and the speed of tool production is particularly impressive, taking just 20% of the time of standard methods.

Sandvik is also leveraging its long experience within powder metallurgy to exploit the powder-based technique used by the DMLS machine to manufacture to almost any design.

John added: "We can also now manufacture almost any design the OEM can create, irrespective of the complexity of the geometry. This means our customers' design teams are not constrained by the manufacturing limitations previously typical in the industry. They have the flexibility to respond with precision to the individual preferences of any one surgeon or the specific needs of a patient.

"Looking ahead we will continue to develop new processes and procedures, exploiting both our long standing commitment to R&D and materials expertise, to the benefit of our customers. Indeed, Sandvik invests 3% of the Group's total sales in R&D."

Sandvik website

Images: sandvik.com

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News: Rapid prototyping and rapid manufacturing event in Rotherham

3T RPD Ltd, a leading provider of laser sintering services throughout the UK and Europe, are hosting a rapid prototyping and rapid manufacturing event in Rotherham this month, enabling local companies to learn about their innovative manufacturing techniques.




In conjunction with the Advanced Manufacturing Research Centre with Boeing, the full-day event will explain and demonstrate the applications, opportunities and benefits of using Selective Laser Sintering (SLS) and Direct Metal Laser Sintering (DMLS) throughout all stages of the product life cycle.

The use of rapid prototyping technologies by engineers, architects and designers is rapidly becoming the norm rather than the exception, revolutionising the speed at which products can be brought to market. And with new opportunities for low volume production, Rapid Manufacturing is becoming a reality for many industry sectors. This seminar will help businesses to make the most of what these technologies have to offer.

The seminar will demonstrate how SLS and DMLS technologies enable the cost-effective, fast and accurate production of durable and complex components, whilst negating the investment in conventional tooling. 3T's technical experts will be available to give advice on specific projects or help with any data issues or questions.

The event takes place at the Rolls-Royce Factory of the Future on the Advanced Manufacturing Park in Rotherham on Wednesday May 12.

3T RPD Ltd website

Images: 3trpd.co.uk

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News: Rotherham expertise could prove the difference in quest for medals

Technical expertise from North America, Europe and the UK has been brought together by Bromley Technologies in Rotherham to complete the final parts of a technology package that could propel Team GB's top medal hopes Shelley Rudman and Kristan Bromley to success in the Winter Olympics.

Based on the Advanced Manufacturing Park in Rotherham, Bromley Technologies combined with fellow AMP residents Materialise UK Ltd and the Advanced Manufacturing Research Centre with Boeing (AMRC) to work with American firm, Mentor Graphics Corporation to provide an aerodynamic package which could provide the extra performance edge needed at Vancouver.

As aerodynamics are relatively easy for competitor teams to copy, the ultimate aerodynamic design was finalised after the last race of the World Cup season leaving a very short turn around time to test the proposed package, analyse the results and make the decision to go ahead with the new designs or not.

Working around the clock, simulations were undertaken by Bromley Technologies Ltd, using FLoEFD software by permission of Mentor Graphics Corporation to assess potential aerodynamic gain, and finalise the potential pan design.

The pan was designed, manufactured and delivered within 48 hours by Materialise in the UK and Belgium, and tests in St. Moritz proved the results of the analysis and simulations. The decision was made to go ahead with the new design for the Olympics and this required a final mould to be manufactured; the pans laid up, made and trimmed, before final fittings and preparations prior to being shipped to Canada.

Again another race against time, the design files were finalised by the Bromley Technologies team and forwarded to the AMRC who used their stat-of-the-art five-axis machine to produce moulds in a matter of days. The Bromley Technologies engineers then laid up the two pans to have them ready to fly out with the athletes.

Mike Maddock, COO of Bromley Technologies said: "I just want to say a huge thanks to Mentor Graphics, Materialise and the AMRC for their help in bringing together the final pieces of the Olympic skeleton technology programme. Without their help and that of our other Formula Ice sponsor companies, we would not have had the successful World Cup campaigns this season, and certainly wouldn't be going into Vancouver as serious medal contenders."

"It's great to be able to showcase such technological expertise on a world stage, and to illustrate through our Formula Ice programme how companies can come together to collaborate and help create something really special."

Philip Hudson, managing director, Materialise UK Ltd, said: "We're pleased that Materialise have supported Shelley and Kristan's Olympic medal bid. It's been a real team effort both here in the UK and in Belgium, and shows the capabilities available through the latest rapid prototyping and manufacturing techniques. We wish them every success this week in Vancouver."

Professor Keith Ridgway, AMRC co-founder, said: "We are delighted to be working alongside a world-class company in Bromley Techologies. With our combined expertise in engineering technology, we have developed an innovative package, and will be eagerly watching Kristan and Shelley's performance and wish them every success at the games."

Bromley Technologies website
Materialise websiteAMRC website
Rotherham

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