The use of industrial robots, specifically multi-axis robotic systems, for object handling and manipulation has significantly increased due to the need to reduce costs, increase production efficiency and avoid difficult and dangerous jobs for humans. Despite the important capabilities of robots, especially in manufacturing, and their use in many types of process automation, their accuracy is relatively poor (in the millimetre range for 1 m^3 working volume), compared to other Cartesian-based Numerically Controlled (NC) automation systems, due to their joint compliance and relatively high structural flexibility in comparison to load capacity. Because of these limitations, robots are restricted in their use for processes that require very high accuracy. Recently, collaborative robots, a special type of multi-axis industrial robot, that can be placed without a safety fence, have become a popular choice due to their flexibility, simplicity to re-program and ability to safely work collaboratively with humans in the same workplace. The joint compliance in these collaborative robots is even less rigid than traditional industrial robots due to the need to have responsive force sensing and coalition-reaction capabilities, further decreasing accuracy capabilities. Most collaborative robots are unable to achieve an absolute positioning accuracy within a 1 m^3 working volume of less than 2.5 mm, making their accuracy more than one order of magnitude higher than their resolution (0.1 mm). This low accuracy limits their utilisation, especially for collaborative robot, so that they are generally restricted to simple pick-and-place tasks. This project will increase by an order of magnitude the absolute positioning accuracy of industrial robots with multi-axis motion to less than 100 micrometres for working volumes exceeding 1 m^3. In this way we will enable precise object manipulation across many application areas.

To design the future of products we need the future of prototyping tools. Across the £30Bn+ consumer product markets, priorities such as demand for non-technical user voice vie against advanced products and tough time/cost targets. These pressures are acutely felt in the prototyping process, where models often number in the 100s for a single product, and are inflexible, technically advanced, and resource-intensive to create. To succeed and evolve prototyping needs to do more, quicker, cheaper, with higher accessibility. This project aims to enhance learning, accessibility, and efficiency during prototyping. It will explore feasibility and value of seamlessly integrating physical and digital prototyping into a single workflow. Recent and rapidly emerging technologies such as mixed reality, haptic interfaces, and gesture control have revolutionised the way we interact with the digital world. It's predicted that this tech will be ubiquitous by 2025, will be disruptive for the next decade, and will drive the way we work and interact across the future digital workplace, with engineering a top-5 sector to realise value. In prototyping, they will break down the physical-digital divide and create seamless experiences, where the strengths of each domain are realised simultaneously. This new physical-digital integrated workflow brings profound opportunities for both engineers and users, supporting technical activities and simplifying communication. Amongst many possibilities users may physically create and feel digital changes to prototypes in real-time, dynamically overlay advanced analyses onto physical models, and support early-stage decision-making with physical-digital, tactile, interactive prototypes. These capabilities will allow more learning per prototype, widen accessibility to technical design and streamline the prototyping process. However, we don't yet know how this exciting vision may be fulfilled, exactly what benefits, value or costs there may be, feasibility of implementation, or effective workflow approaches. The project will explore physical-digital workflow by creating and investigating several demonstrator platforms that combine and apply haptic, mixed reality, and gesture control technologies in targeted prototyping scenarios. Technologies will be explored to understand capability in isolated sprints, before prioritisation and development into focused demonstrator tools that allow us to explore integrated workflow across real prototyping cases, spanning activities, types, and stakeholders. Demonstrators will be evaluated and verified with end-users, industry partners, and the public to establish learning, speed, cost, and usage characteristics. Project outcomes will comprise workflows for integrated prototyping with knowledge of value, effectiveness, feasibility, and future opportunities. A 'toolkit' of implementations will also provide exemplars for industrial partners and academia and lead the effective use of integrated physical-digital workflow in engineering. All software and hardware will be open-sourced via Github and the project webpage, letting global researchers and the public create their own systems and build upon the work. Future work will extend capabilities in line with outcomes of the work, leading to the next generation of engineering design and prototyping tools. Industrial Partners The Product Partnership (Amalgam, Realise Design, and Cubik) and AMRC will bring prototyping, engineers, and end-user expertise and benefit from the workflows and technologies that are developed. OEMs Ultraleap and Autodesk will bring immersive technology expertise and access to cutting edge design systems, and will benefit from case study implementations and studies and future application opportunities. Bristol Digital Futures Institute will facilitate collaboration across 20+ partner businesses and the public, with outputs supporting their mission for digital solutions that tackle global problems.

The NHP-WEC project aims to advance data-driven monitoring and control in connection to both device technology and sea state predictions for WEC arrays. The research proposed is simultaneously generic while also significantly contributing to the development of an existing concept device that has shown potential, namely the multi-axis TALOS that has been developed and tank tested at Lancaster University (LU). TALOS is a novel multi-axis point absorber-style built as a 1/100th scale representation, with a solid outer hull containing all the moving parts (like a submarine or a PS Frog style WEC device). The internal PTO system is made up of an inertial mass with hydraulic cylinders that attach it to the hull. The mass makes up a significant proportion of the device, hence it moves around as the hull is pushed by various wave motions. The motion of the ball moves hydraulic cylinders causing them to pump hydraulic fluid through a circuit. The flow of this hydraulic fluid is used to turn a hydraulic motor, which is coupled to an electrical generator, to generate electricity i.e. an inertial mass PTO approach. Key strengths include: The arrangement of the rams allows for the mass ball to move in multiple directions, allowing energy to be captured from multiple degrees of freedom. The flow of hydraulic fluid will change as the ball's motion changes, so an internal hydraulic smoothing circuit is utilised to regulate the output. The latest design has proven to be successful in wave tank testing and the PTO system yields a smooth output in response to time-varying inputs from waves. An analytical model has also been developed to combine data from the hull model and hydraulic rig, yielding a predicted power output of up to 3.2 kW. However, TALOS is at a very early stage of development and requires further research to advance its Technology Readiness Level (TRL). The design, development, deployment and operation of WECs, such as TALOS and their potential commercial use requires a holistic understanding of the marine environment, including on-line monitoring to enhance control combined with prediction. Potential WEC deployment sites and energy resource from single devices and arrays must be determined. Operational conditions, including wave characteristics must be quantified to estimate dynamic loads on WEC, constraining manufacturing and their real-time operation. In this context, SmartWave, developed by the UoH, with the ORE Catapult and Orsted, is a tool capable of deriving high resolution sea state conditions from satellite images using machine learning. Key strengths: SmartWave is based on a novel forecasting methodology, capable of resolving sea state within offshore windfarms for sector O&M logistics. It integrates recent advances in all-weather satellite monitoring to map and study the temporal and spatial distribution of sea surface wave characteristics. However, existing limitations must be addressed to advance the TRL of WEC capabilities and hence fully exploit this new technology. For example, it has been developed to characterize significant wave height, whilst further research is essential in order to extract other sea state parameters, including wave height, direction and frequency. Nonetheless, since it is capable of global reach remotely, without the use of in situ sensors, SmartWave is uniquely placed to identify the selection of appropriate deployment sites depending on the device size and specification, for optimal production of electricity. The NHP-WEC project brings together key aspects of WEC technology and the global deployment potential of SmartWave, allowing integration of novel methodologies across optimisation, control, condition monitoring and resource forecasting. These advances will together drive evidenced reductions in costs and hence provide confidence on the benefits of wave energy technology to developers and investors.

This fellowship will create a academic team to lead a new research theme dedicated to manufacturing the future. It focuses research on geometrical product specification and verification (GPS) systems to control geometrical variability in manufactured products that facilitate emerging industrial requirements in 21st century. For example, geometrical products used in: next generation freeform optics, interfaces in fluid-dynamics (energy-efficient jet engines, aircraft fuselages and wings), long life human-joint implants, microelectronics and MEMS/NEMS devices in nanotechnology applications. The UK frontier industry is seeking next generation of products having much higher functional capabilities with much lower manufacturing costs. This is driving manufactured products to have more integrated properties but more complex geometries. Without the tools to specify, optimise and verify the allowable geometrical variability, the ability to manufacture complex geometries is not possible. This Fellowship is to explore the mathematical fundaments for the decomposition of geometry (i.e. size, shape and texture) and create ground-breaking technology to control geometrical variability in manufactured products. The novel approach is to link fundamental geometrical mathematics direct to key component's design, manufacturing and verification from different industrial sectors (i.e. aerospace, optics, healthcare and catapult centre). In this case, the different types of geometrical decompositions (at the ultimate causation level via information content) to specified geometrical surface requirements (spectrum, morphological and segmentation decompositions). This fellowship attempts to establish this emerging new theme that has never happened before, that requires sophisticated industrial manufacturing skills with in depth fundamental academic knowledge. In practice no surface is manufactured perfectly: there is always some variability in the surface. Tolerance zones only control the size of this variability and not its shape. The approach proposed for the Fellowship is to break up (decompose) the surface variability, for each of the symmetry classes, to enable the shape to be controlled. The challenge is to produce a complete range of geometrical decompositions (together with the associated theory and practical algorithms) that will solve the mathematical grand challenge. For example contact (mechanical, electrical, thermal, etc.) requires the surface envelope to be decomposed. Other functions require decomposition into surface features ('hills and dales') at different scales. This system aims to provide the necessary mathematical foundations for a toolbox of techniques to characterise geometric variability: going far beyond simple tolerance zones as currently defined in national and international standards. The eight letters of support from different sectors: Rolls-Royce, NPL (Engineering Measurement), NPL (Mathematics and Modeling), Taylor Hobson, British Standards Institute, Catapult - Advanced Manufacturing Research Centre, UCL (Institute of Orthopaedics and Musculoskeletal Science: Royal National Orthopaedic Hospital), Prifysgol Glyndwr (OPTIC) all highlight that there is an urgent need for the proposed technology from a point of view of wide UK industry.

Coatings are key to the performance of most products and they contribute to sustainability by enhancing the efficiency and extending the life of the products that they protect, as well as by enabling the reduced use of scarce bulk materials. Therefore, coatings are a vital part of the nation's manufacturing industry, contributing to many sectors, including aerospace, energy, automotive and construction. However, until now the UK coatings industry has been severely lagging behind compared to High Value Manufacturing sectors in terms of all aspects of design, development, manufacture, and implementation into products, particularly in terms of the degree of digitalisation achieved (as epitomised in the "Industry 4.0" concept). This EPSRC NetworkPlus in Digitalised Surface Manufacturing is needed because currently there is no UK University that has all the required interdisciplinary expertise in surface engineering and digital manufacturing and there is a lack of 'connected' knowledge in the area of digitalisation of coating manufacturing processes in UK industry. The Network will bring together academic and industrial expertise in multiple disciplines to address the challenges of digitalising the UK coatings manufacturing sector. The Network will create a community that will be able to carry out innovative leading-edge research which will ultimately allow the coatings manufacturing industry to achieve the best-in-class levels of High Value Manufacturing. The development of a UK-wide network around digital methods for surface manufacturing can bring optimum manufacture processes ("right first time") to the surface engineering and advanced coatings community in the UK. The creation of this NetworkPlus will serve to capture and understand the current manufacturing scene and pump-prime digitalisation activity in this area. The new interdisciplinary research community developed within the Network will assist the UK PLC to develop manufacturing methods which are predictable, digital-enabled and more productive, providing the pathway to class-leading coating manufacturing processes. This will bring resilience and improved productivity across all key UK industrial sectors. End-users of the coatings industry span all sectors and thus the economical and societal impact of the Network will be wide-ranging. In turn, the digitalisation of the coatings manufacturing industry will also mean that the benefits of coatings on products are thoroughly recordable and accessible, as is needed to enable statistically robust knowledge of manufactured product lifetimes and performance. This is vital to enabling full life-cycle assessment of coated products and the sustainability implications of the coatings applied, contributing to the long-term aims of a resilient manufacturing.