Functionally graded material - Electroformed component robotic manufacturing

在这个项目中，先进的机器人和自动化技术被用来解锁创新的制造工艺。Ultima Forma拥有一项专利技术，使用电沉积技术以低能耗、低浪费的工艺将金属工程部件制造成净形状。这一过程允许按顺序沉积不同金属的微观层。这种多层结构的设计可以在很大范围内控制材料的性能，获得传统材料所不具备的性能。此外，可以在零件内的不同位置改变特性，以形成作为单个实体的多功能零部件。这种颠覆性技术在英国是独一无二的，为先进工程部件的设计和制造提供了一种全新的方法。空中客车防务和空间公司与Ultima Forma合作开发了一种多功能部件，将现有的6个部件合并为一个实体。该组件减少了部件数量，节省了重量和空间，并缩短了组装时间，在美国21.4亿美元的卫星波导市场上为空客提供了竞争优势。Ultima Forma已经建立了一个小型概念验证机器人单元来演示这一概念。该项目将在贝辛斯托克的新工厂建造一个先进的机器人单元，以实现按空中客车公司要求的质量标准批量生产功能梯度波导的自动化。整个机器人电沉积过程将采用先进的自动化控制，以确保生产过程中每个部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，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质结构(如A380飞机的机翼，以及离岸风力发电场的叶片)。然而，这些复合材料很容易受到环境的侵蚀破坏。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。将在项目期间制作演示该技术的实例，并将其推广到我们现有的网络，并在相关的贸易展会上以及通过一系列媒体渠道展示。

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.