Functionally graded material - Electroformed component robotic manufacturing

在这个项目中，先进的机器人技术和自动化技术被用来开启一个创新的制造过程。Ultima Forma拥有一项专利技术，利用电沉积技术，以低能耗、低浪费的方式制造金属工程部件。这个过程允许不同金属的微观层依次沉积。这种多层结构的设计可以在很大范围内控制材料的性能，获得传统材料无法获得的性能。此外，这些属性可以在部件内的不同位置变化，以形成作为单个实体的多功能组件。这种颠覆性的技术在英国是独一无二的，并提出了一种全新的方法来设计和制造先进的工程部件。空中客车防务与航天公司与Ultima Forma公司合作开发了一种多功能组件，该组件将6个现有组件组合成一个单一实体。该组件减少了零件数量，节省了重量和空间，缩短了组装时间，为空客在21.4亿美元的卫星波导市场提供了竞争优势。Ultima Forma公司已经建立了一个小型的概念验证机器人细胞来演示这个概念。该项目将在我们位于贝辛斯托克的新工厂建立一个先进的机器人单元，以按照空客要求的质量标准批量生产功能分级波导。整个机器人电沉积过程将采用先进的自动化控制，以确保在整个生产过程中每个零件的可重复性和质量保证。自动化生产过程可以应用于其他工程问题，其中功能级材料的优势可以提供新的解决方案。例如，复合材料越来越多地用于轻型结构（如A380飞机的机翼和海上风力发电场的叶片）。然而，这些复合材料很容易受到来自环境的侵蚀破坏。这些复合材料上的金属涂层可以提供保护并延长这些结构的使用寿命，同时显著减少碳足迹。在项目期间，我们将制作示范技术的例子，并在我们现有的网络中推广，并在相关的贸易展览以及一系列媒体渠道中展示。

In this project advanced robotics and automation are used to unlock an innovative manufacturing process. Ultima Forma has a patented technology using electro-deposition to manufacture metallic engineering components to net-shape, in a low energy, low waste process. The process allows microscopic layers of dissimilar metals to be deposited sequentially. The design of this multi-layered structure can control the properties of material across a wide range, accessing properties that are not available in conventional materials. Furthermore, the properties can be varied from place to place within a part to form a multi-functional component as a single entity. This disruptive technology is unique in the UK and presents a completely new approach to the design and manufacture of advanced engineering components.Airbus Defence and Space, in collaboration with Ultima Forma have developed a multi-functional component that combines 6 existing components into a single entity. This component reduces the number of parts, saves weight and space and reduces assembly time, providing competitive advantage to Airbus in the US$2.14bn satellite waveguide market.Ultima Forma have already established a small proof-of-concept robotic cell to demonstrate the concept. This project will build an advanced robotic cell at out new factory site in Basingstoke to automate the production of functionally graded waveguides in batches to the quality standards required by Airbus. The entire robotic electrodeposition process will be controlled using advanced automation to ensure repeatability and quality assurance of every part is attained throughout the production process.The automated production process can be applied to other engineering problems, where the advantage of functionally grade materials can provide new solutions. For example, composite materials are increasingly used for light-weight structures (such as the wings on the A380 aircraft, and blades for off-shore wind farms). However, these composite materials are vulnerable to erosion damage from the environment. Metallic coatings on these composite materials can provide protection and extend the operating lifetime of these structures with significant reduction of carbon footprint. Examples to demonstrate the technology will be produced during the project and be promoted to our existing network and displayed at relevant trade shows as well as through a range of media channels.