3D Printing, plastics and electrical circuitry are some of the central specialisms that have played an influential role in responding to these requirements. However, problems with getting resilient, robust and consistent integrated “tracks” (electrical conductors connecting components together in a system) have left a gap in the market for an innovative manufacturing solution.
The Integrated Manufacture of Polymers and Conductive Tracks (IMPACT) project was established in October 2017 with the aim of developing 3D Printing technology that has the ability to print plastic products with integrated electrical circuitry.
Led by Iterate Design and Innovation Ltd, in collaboration with WMG at the University of Warwick, C Enterprise (UK) Ltd and Printed Electronics Ltd, the project was made possible thanks to a grant of nearly £900,000 from Innovate UK.
Utilising 3D Printing to improve the technology and cut costs
To respond to global requirements and demonstrate the ability to print plastic products and integrate electrical circuity through 3D Printing technology, the IMPACT project group opted to develop a bionic hand solution with enhanced functionality.
Within the project, Iterate Design and Innovation Ltd developed the design of the hand, including the integration of the electrical circuitry and sensors. Printed Electronics Ltd developed the technology for printing the electrical circuitry within the 3D Printing process and C Enterprise (UK) Ltd developed the multi-axis, multi-material 3D Printer that enables the hand to be realised in 3D.
3D Printing technology was utilised for its customisability, allowing for more movability in the limb and also offering a cost effective mode of production. The multi-axis 3D Printer also ensured a smooth surface for the tracks to be deposited onto.
WMG supporting the consortium
WMG engineers supported the project by testing the durability of the printed electrical circuitry to understand how well they will endure the bending and flexing that they might experience in use, developing the process at WMG’s mechanical testing facility at the International Manufacturing Centre.
They also developed a website (e-platform) so that people can interact with the manufacturers to order a 3D Printed hand, allowing them to insert the measurements of their arm, and select what colour they want their hand to be, providing them with a tailored and personalised product. Dr Greg Gibbons, Associate Professor at WMG comments:
“WMG are delighted to be a partner in the IMPACT project, helping to deliver this innovative and revolutionary technology, which is undoubtedly helping put UK PLC at the forefront of 3D Printing research and development globally.”
Made to measure in 10 hours
As a result of successfully implementing this 3D printing process, the IMPACT project culminated in March 2019 and has been able to create a bionic hand that can be made to measure in 10 hours in a choice of colours, and can grip using a moveable thumb.
Designers and engineers from WMG and UK industry have been able to entirely 3D Print the device, embedding the electrical circuitry linking the motion controlling muscle sensors with the motors and battery into the structure of the bionic hand to control an articulated thumb, enabling it to function similar to a human hand and providing a durable and aesthetic solution.
Gethin Roberts, Project Lead and MD of Iterate Design and Innovation comments:
“The IMPACT project has resulted in the creation of an exciting new technology that has the ability to print electro-mechanical parts and assemblies, which wasn’t previously possible. Through laying down conductive ink tracks within polymer structures, parts produced are fully functional straight off the machine bed; offering huge productivity benefits.”
Influencing aerospace, defence and automotive sectors
The 3D Printing and multi-axis technology developed throughout the IMPACT project has also led to the establishment of spin-off Joint Venture ‘Q5D Technology’, which was launched in April 2019.
Since being set-up by IMPACT consortium member C Enterprise (UK) Ltd, alongside laser micro machining and electronic printing company M-Solv, the Joint Venture has generated over £150,000 in sales with clients throughout the automotive, aerospace and defence sectors utilising its IMPACT-inspired specialism in printing electronics onto complex surfaces.
In taking the IMPACT platform and refining the prototypes with a view to stimulating high commercial usages, Q5D has developed a prospective pipeline of 40 customers, and has landed two high profile clients in the aerospace industry.
Agreed in June 2019, Q5D will be working with aerospace giant Airbus to utilise IMPACT technology to take existing components and lay fibre optics, utilising 3D Printing and 5-axis technology to provide intelligence on stress and strain in aircraft through the installation of sensors.
Following this, Q5D has also just received a £1.9m two-year ATI Grant (launching in December 2019), which enables the company to work with Safran, tier-1 supplier of systems in the aerospace and defence sectors. Q5D will be utilising the technology developed in the IMPACT project to conduct wiring for composite panels on First and Business Class aircraft seating, to ensure that the aircraft interiors are as refined as possible. Commenting on the legacy of the IMPACT project, Stephen Bennington, CEO of Q5D Technology said:
“The IMPACT project is a great example of how collaboration and a shared vision can result in not only a remarkable piece of innovation, but can inspire new technological processes that carry high commercial appeal throughout industries across the world.
“We are experiencing first-hand how this technology is attracting huge companies, and it’s fantastic that the legacy of the IMPACT project is now living on through our thriving organisation.”
