The HySMART (Hydrogen Stack Manufacturing using Advanced Robotics Technology) feasibility project is driven by an urgent need for fuel cell (FC) system producers and associated supply chain to drive down cost from \>€150/kW to <€50/kW (2025), and <€45/kW (2030) at 100k units/yr. (HE.2018), enabling FC vehicles to be offered on a cost competitive basis. Current processes are bespoke and limited in volume and size, providing limited opportunities to reduce costs, with current commercial sales of global automotive FC's -- in 1,000's/year. This project will study real-world applications of automation and inline testing for volume production of hydrogen FC stacks, to include end user requirements. Focusing on the development, integration and application of robotics, software controls and machine learning solutions for producing FC stack technologies. This will be achieved through a feasibility study to include: * Developing a technology roadmap to demonstrating robotics stack manufacturing FC capability * Key component development (MEA's, endplates, bi-polar plates) for in-house automated production to feed into final modular stack manufacture * Implementation of advanced inline testing capabilities, to provide a no faults forward stack production capability * Analysis of co-operative interaction capabilities and associated learnings in this key area of the FC system production process * Developing advanced automation concepts in 3D and test virtual manufacturing scenarios (digital prototyping) * Study end user requirements specific to active implementation into light/medium duty automotive applications The main HySMART deliverable will be key outputs from a comprehensive demonstrator study, detailing advanced product designs and validating key technical challenges; developing FC components ('design for assembly/disassembly'), installation/implementation of in-house robotics manufacturing, and inline testing capability producing high quality conformable modular FC stacks for light/medium duty vehicle applications. HySMART will result in the following benefits: * Instill automotive sector confidence in hydrogen FC technology, accelerating commercial uptake. * Provide industry stakeholders (manufacturers, OEM's, supply chain, etc.) with the operational and technical requirements of using advanced robotics in UK FC stack volume manufacture. * Enhanced conformational capabilities for FC stack developers to provide diverse and system range. * Roadmap to production of working robotic FC stack demonstrator with enhanced inline testing capabilities. * Implementation and roll-out of novel production processes, providing advanced cost-effective modular FC stack systems. * A FC stack system architecture, manufacturable by automation, delivering improved efficiency, and reproducibility. * Opportunities to develop and expand products into additional markets and sectors. Total project size will be £800,607, last 12 months and involve 5 UK partners (Bramble Energy, Microcab, Loop Technology, UCL and HSSMI).

The adoption of advanced composites structures is spreading across a wide range of industries from aerospace to automotive and wind energy. This is driven by both an organic development model and a regulatory one. The use of carbon fibre reinforced plastic (CFRP) has the potential to massively reduce the weight of structures without compromising performance. Lower weight means lower fuel burn and therefore lower emissions, sometimes with even higher performance than would be achieved had metallic components been utilised. There are many stages involved in the production of a CFRP component. Operations can include cutting of fabric into patterns, layup of material into a mould, inspection, trimming and finishing. All of these can include an element of handling, a job that to a large extent is performed manually. The objective of the project proposed here is to develop a flexible gripper system suitable for use in automated handling operations. The gripper will be modular, scaleable and suitable for mounting on a variety of deployment systems be they robotic or gantry based. The system will be infinitely configurable for the material shape and surface profile to the extent it can pick or place onto a surface with curvature in two dimensions. The gripper can be operated in normal or inverted horizontal planes or place onto vertical surfaces as the application demands. This will mean the same gripper concept can be used for a wide range of components ranging from wing skins and engine nacelles in the aerospace world to roof and body panels in the automotive environment. The gripper being configurable allows for numerous sizes and shapes of component to be processed using a single gripper.

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Many of the current manufacturing techniques used in industries were developed for standard and conventional materials, some of which are now being challenged by novel and more advanced counterparts which can be difficult to process by standard means. A next-generation, advanced manufacturing technique is required to fully exploit the potential of these innovative materials, which include examples such as CFRP-metal stacks. The aim of the RoboMade project is to exploit a decade of advanced R&D activities in robotics, advanced machining and automation to develop a novel hybrid ultrasonic assisted robotic machining system for. RoboMade will offer a low-cost and accessible solution, delivering high-value, to meet the ever-increasing demand from customers for precision machining of exotic materials, associated with significant capital and operational cost savings. The digital infrastructure underpinning the system will provide users major benefits related to flexibility, configurability and autonomous operations