2023 Programme

Time Information
09:30 - 09:45
09:45 - 10:15

Aerospace & Defence 1

Functional Additive of Soft Materials for Future Defense Applications
Christopher Tabor, Senior Research Scientist, Air Force Research Laboratory, Materials and Manufacturing Directorate


This presentation will provide a brief overview of the Polymer and Responsive Materials & Process Research Team in addition to the functional additive manufacturing technologies for soft materials that being developed across the Air Force Research Laboratory. Specific examples include photo-curable hydrogels for soft-robotics, materials for flexible and stretchable electronics, printing on conformal surfaces, and autonomous direct ink-write technologies will be addressed in detail. Finally, a forecast of materials challenges for the AM community with respect to defense applications will be presented. 

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Functional AM
2. Photo-curable materials
3. Flexible/stretchable electronics
4. Novel AM techniques
5. Materials Challenges
10:15 - 10:45

Aerospace & Defence 1

Moderate your Enthusiasm – Implementing AM Successfully
Jon Meyer, CEO , APWORKS GmbH


Additive Manufacturing (AM) has gone through a hype cycle, which has created confusion and misinformation about its true benefits. Jon Meyer, an industry expert with a wealth of experience in implementing AM technology successfully, will set the record straight. Drawing on his extensive background in this field, Jon will share valuable insights into the key factors that determine when and how AM can add value, as well as when it doesn't. Attendees will come away with a better understanding of the potential benefits of AM and some practical tips on how to leverage this technology to improve their own products.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. What are the main business benefits of AM technologies
2. Why do companies struggle to adopt AM successfully
3. What are the most common misconceptions about AM
4. What does a good application of AM look like
5. Strategies for successfully implementing AM
10:45 - 11:15
COFFEE BREAK ˗ˏˋ☕ˎˊ˗


11:15 - 11:45

Next Generation AM - Volumetric Additive Manufacturing

Factors determining the spatial resolution, accuracy and repeatability of computed axial lithography
Hayden Taylor, Associate Professor of Mechanical Engineering, University of California, Berkeley


Computed axial lithography (CAL) is a volumetric additive manufacturing process for photopolymers that defines 3D geometries through tomographic reconstruction of a light dose in a vat of material. Current research seeks to expand the range of macromolecules processable with CAL, demonstrate initial applications, and, crucially, probe the minimum feature sizes and maximum component sizes that are practically achievable. This talk will offer a framework for assessing the geometric capabilities of CAL, addressing both physical and computational considerations. I will describe the position- and orientation-dependent spatial modulation transfer function that is inherent in CAL. I will also discuss computational approaches to optimizing light dose delivery for complex and heterogeneous geometries.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Spatial resolution in CAL depends on position and geometric orientation in the printing volume
2. The computational phase of CAL may be accelerated by using a voxel-free representation of the desired geometry
3. Where dimensional accuracy is paramount, it may be advantageous to focus on optimizing light doses at the surface of the desired object instead of on a regular spatial grid
4. Diffusion of oxygen and other species can play an important role in determining spatial resolution and accuracy in objects printed with CAL
5. Optimization of the delivered light dose distribution needs to consider the effect of subsequent post-processing on the final geometry of the component
11:45 - 12:15

Next Generation AM - Volumetric Additive Manufacturing

Materials Progress and Process Modeling in Volumetric Additive Manufacturing
Maxim Shusteff, Group Leader, Materials Engineering and Biomanufacturing , Lawrence Livermore National Laboratory


The volumetric additive manufacturing (VAM) paradigm in photopolymer 3D printing refers to creating a 3D object all at once, without layering.  This approach has now proliferated into a variety of 3D printing methods, and a breadth of possible materials with which to employ them.  Here we will examine the defining characteristics of VAM printing, and explore the recent advancements in developing VAM-compatible materials for biological applications, and for challenging engineering requirements.  We will also examine the benefits of modeling the photopolymerization process in the volumetric modality and insights that emerge for understanding layered 3D printing processes.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Volumetric AM is defined by two essential characteristics: simultaneity of producing the 3D structure, and pre-assembly of feedstock material.
2. VAM printing of hydrogel biomaterials for tissue engineering requires advancements like overprinting, multiple materials, and precise photon dose control.
3. Advanced engineering materials such as glass and silicones printed via VAM are gaining in complexity and shape control
4. Combined finite-element modelling of volumetric light dose absorption with diffusive molecular transport creates useful predictions of AM photo-resin behavior
5. Reduced-order modelling based on this learning will be critical for continued progress
12:15 - 13:45
LUNCH BREAK 🍽️


13:45 - 14:15

New Processes and Functional Materials

Design for Metal Jet Printing
Denis Cormier, Professor, Rochester Institute of Technology


Metal Jet Printing (MJP) is an emerging metal additive process with distinct differences from conventional metal AM processes. This talk will cover what those differences are, and how they affect part design and what can be produced. As an example, the absence of a powder bed means that closed-cell lattice structures that are impossible to produce with powder bed fusion processes can be metal jet printed. Other DFAM topics such as minimum unsupported surface angles, lattice beam diameters, and design for printed electronics will be covered.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. The basic steps of metal jet printing
2. How closed-cell lattices can be printed
3. Minimum unsupported surface angles
4. Material capabilities and limitations
5. How lattices encapsulated within solid skins may be produced
14:15 - 14:45

New Processes and Functional Materials

Advances in multi-material microstereolithography
Shoji Maruo, Professor, Yokohama National University


Multi-material microstereolithography can provide highly functional 3D microdevices, which are expected to be applied in many fields such as medicine, photonics, micromachines, and sensors. However, there are still technical issues such as material waste and long fabrication time. Recently, we have developed a multi-material two-photon lithography technique using droplets that minimizes material waste. It was demonstrated that micro-optical components could be fabricated using this technique. We have also developed new photocurable materials such as silica slurry and conductive polymer. The combination of multi-material 3D printing and new functional materials is useful for the fabrication of highly functional microdevices.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Multi-material 3D printing
2. Micro stereolithography
3. Two-photon lithography
4. Glass 3D printing
5. Conductive polymer
14:45 - 15:15
COFFEE BREAK ˗ˏˋ☕ˎˊ˗


15:15 - 15:45

Novel AM Computation

Using AI to build self-aware 3D printers
Dr Douglas Brion, Founder & CEO , Matta


Additive manufacturing is being applied across industries, but the technology is still limited by its vulnerability to diverse errors. Expert operators are required to manually detect and correct errors and tune process variables for new parts and materials. This talk will discuss the application of recent advances in large AI models and deep learning to tackle these problems. Like humans, these AI models learn about the physics and processes behind “how a part is made”, opening the door to autonomous error detection and correction, improved part quality, and 3D printers that can learn to use new materials completely by themselves.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Generalisable AI models can reliably detect and range of errors and their causes.
2. If trained correctly, AI networks can enable closed-loop feedback for error correction.
3. Physics and explainable AI can be used to try and understand neural network predictions.
4. Generating large data sets correctly (and autonomously) is half the problem!
5. AI techniques can be applied across geometries, materials, printers, and setups.
15:45 - 16:15

From Academia to Industry: Exploring the Journey of a Successful Innovator in Additive Manufacturing

From Academia to Industry - a life in Additive: Interview with Dr Brent Stucker
Brent Stucker, Independent Consultant, 3DX Consulting


From two decades at the forefront of international research, to the launch of his own technology firm, and - most recently - a spell  as CTO at 3D printing giant 3D Systems, Dr Brent Stucker has a uniquely well-rounded perspective on the challenges and opportunities facing the AM sector.

During this session Brent, now an independent consultant, will share key thoughts and observations on the sector - from the importance of academic industry collaboration, to the challenges of tapping into funding and investments, and the technologies that will shape the future of the field - with the editor of The Engineer magazine Jon Excell.
16:45 - 17:45
Networking Drinks & Tour of the Labs


19:30 - 22:00
Industry Dinner


MemSaab Restaurant,
12-14 Maid Marian Way,
Nottingham NG1 6HS
Time Information
09:30 - 10:00

Global Trends

The UK Additive Manufacturing Landscape
Iain Todd, Director , EPSRC MAPP Future Manufacturing Hub


Over the past year we have gathered information on the UK AM Innovation landscape and its impact. The findings, compiled by Added Scientific, show that we perform well compared to international peers in all academic metrics– publications, grant income, collaborative projects with industry, PhD completions, etc. but that, despite some excellent examples to the contrary, nationally we perform relatively poorly for spin out and value generation activities – particularly when considering long term, sustainable businesses that remain UK owned and operated. Here I will present our findings and suggest future actions to encourage and support a healthy, vibrant UK AM ecosystem. 

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Where the UK sits in terms of academic outputs and strengths
2. Our IP position as a community
3. where the gaps in the UK innovation chain lie
4. The weaknesses we have identified in the UK research ecosystem
5. Key recommendations for change
10:00 - 10:30

Global Trends

Empowering Distributed Manufacturing with 3D Printing
Dr. Wilderich Heising, Partner and Associate Director, Boston Consulting Group


In the recent years, we have seen strong technological advancements in additive manufacturing. Manufacturing companies can now build on the technology to form distributed production networks to make their operations more efficient, more resilient, and more sustainable. We present a framework ensuring the right design choices and identify most suitable applications for distributed manufacturing. We address critical issues like IP protection and certification and business viability. The presentation also includes a case study of manufacturing companies starting the journey and service providers in the field.

3 THINGS YOU WILL LEARN DURING THIS SESSION:

1. The ability to describe the current state of the 3D Printing market in terms of size and development along the entire additive manufacturing value chain
2. The ability to describe the three different dimensions of distributed manufacturing and how they can be applied in 3D printing
3. The ability to leverage different dimensions of distributed manufacturing in 3D Printing to their advantage to boost efficiency, resilience and sustainability in their product supply process
10:30 - 11:00
COFFEE BREAK ˗ˏˋ☕ˎˊ˗


11:00 - 11:30

Aerospace & Defence 2

Overview of Additive topics at Airbus Defence & Space
Alexander Pluke, CEO , Additive Flow


This presentation will give an overview of the AM activities currently within Airbus Defence and Space, including the latest updates on Scalmalloy, RF systems and WAAM. Airbus Defence and Space will also reveal the results of a project that they have worked with Additive Flow on cost optimization.
11:30 - 12:00

Aerospace & Defence 2

Development and Productionisation of AM in Submarines
Dave Poole, Additive Manufacturing Manager, Rolls-Royce Submarines


This presentation will cover how the dedicated additive manufacturing team within Rolls-Royce Submarines has developed and implemented Laser Powder Bed Fusion for high integrity, safety critical nuclear applications.  The presentation will also describe the key enabling research & development programmes currently in progress to support the growing number of exciting applications being targeted for Additive Manufacture across the Nuclear business.
12:00 - 12:30

Aerospace & Defence 2

Why Productivity is the Real Barrier to AM Adoption
Bradley Hughes, Principal Research Engineer - Additive Manufacturing, GKN Aerospace


Additive Manufacturing promises numerous benefits compared to incumbent manufacturing processes: greater design freedom, functional integration and reduced material waste are often touted alongside other benefits. Why then are we still waiting the mass adoption of Additive Manufacturing in aerospace? In this presentation GKN will present some of our recent case studies utilising AM to demonstrate the above benefits, before discussing the ongoing battle to remove the persistent barriers to AM. The entire AM value chain has a role to play in progressing the adoption of AM, we just to need to make sure we focus on the right problems.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. The motivation of PBF in aerospace
2. GKN case studies: our latest powder bed successes
3. The key barriers to adoption of L-PBF in aerospace
4. What AM needs to succeed in the short term in aerospace
5. Where the AM eco-system needs to focus
12:30 - 13:45
LUNCH BREAK 🍽️


13:45 - 14:15

Process Development

Shaping laser beams for controlling 3D printing
Thej Tumkur, Staff Scientist, Lawrence Livermore National Laboratory


Laser metal additive manufacturing (AM) requires precise coupling of energy to produce desired mechanical and morphological properties of printed structures. However, Gaussian-like process laser beams commonly employed in metal AM limit control over thermomechanical processes that govern microstructural and macroscale properties. In this talk, I will present our team’s efforts in using tailored spatial intensity profiles of the process laser beam, for improving control over melt pool dynamics. I will also discuss our efforts on implementing complex phase and polarization patterns for potentially greater degree of process control during metal 3D printing.  

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Laser beam shaping can affect melt pool dynamics in metal AM
2. Shaping the amplitude of light can broaden the process window for conduction mode melting, mitigate spatter and reduce porosity
3.  Our initial observations lead to the question – can the polarization and phase of light be utilized to achieve greater control over melt pool dynamics?
4. We demonstrate shaping light in complex ways (amplitude, phase and polarization) can be used as an optical knob for controlling microstructure, but the intricacies of this observation is worthy of a debate/discussion! 
5. What other degrees of freedom of light can be used for process control during laser-based manufacturing? Kindly attend the talk to discuss further!
14:15 - 14:45

Process Development

Unlocking Binder Jet’s True Potential
Professor Kate Black, Professor of Manufacturing , University of Liverpool


Binder jet printing has the potential for high-throughput manufacturing but currently produces parts with high porosity and large shrinkage rates. In this work the conventional organic binder is replaced with a functional metallic binder, composed of; molecular, nanoparticle and micro-particle metallic components. The effect of the addition of nano and micro-particles on the binding mechanism and the overall density and shrinkage of the printed structures are assessed using a correlative workflow analysis. This correlative approach enables the optimisation of this novel binderjet printing process, providing better certification of printed materials and their wider adoption in sectors such as aerospace and automotive.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. The importance of material selection in Binder jet printing
2. The importance of characterisation in Additive Manufacturing
3. The need for correlative workflow characterisation in Additive Manufacturing
4. What functional binders are
5.  How functional binders can be used to optimised part performance
14:45 - 15:15
COFFEE BREAK ˗ˏˋ☕ˎˊ˗


15:15 - 15:45

Advanced Applications

Advanced Polymeric Materials for Additive Manufacturing
Victor Sans Sangorrin, Distinguished Researcher GenT, Universitat Jaume I


The development and industrial uptake of additive manufacturing (AM) relies on the development of new materials able to respond to a rapidly changing world. However, this is a tedious and labour-intensive process. It would be highly convenient to develop materials and formulations that can have a broad range of applications. Here, we will introduce the recent developments in our group related to the development of printable polymeric based materials with molecularly designed ionic functionalities. The polymers interact synergistically with molecular and nanostructured materials, enabling a broad range of applications, including carbon capture and transformation, photocatalysis, antimicrobials and optoelectronics.

4 THINGS YOU WILL LEARN DURING THIS SESSION:

1. Advanced polymeric materials
2. Formulations for stereolithography AM
3. Stabilisation of molecular and nanostructured materials
4. Applications in decarbonisation, antimicrobials and optoelectronics
15:45 - 16:15

Advanced Applications

How filtration membranes are being modernised thanks to Additive Manufacturing
Dr Ian Ashton, Senior Engineer , Evove


The filtration and separation of liquids plays a pivotal role in our economies, from purifying and recycling water, filtering food & beverage, desalination, making semiconductors and green hydrogen, to extracting lithium to power batteries. But the conventional membranes used to do so are based on outdated manufacturing techniques that make them very imprecise and inefficient, not to mention troublesome to operate and requiring frequent replacement. Evove is pioneering the use of additive manufacturing to transform the performance and applicability of large-scale membranes. In this seminar the advancements achieved using various AM techniques will be presented.

5 THINGS YOU WILL LEARN DURING THIS SESSION:

1. AM design freedom allows for the manufacture of membrane structures with improved fluid flow dynamics
2. Conventional membrane performance can be improved via additively manufactured inserts
3. CFD optimised meshes are being used to improve filtration flux and reduce system pressure drop in spiral wound filters
4. Low energy binder jet printing can produce ceramic filtration components which are topologically optimised and can last ‘indefinitely’
5. Improved filter efficiency and reduced operational energy are essential to decarbonise the filtration industry
16:15 - 16:30
End of Conference