Synbiosys was given a polymer. Its composition and manufacturing process were not disclosed. The material was to be integrated into an aerospace component.
A standard matrix of 700 tests is provided to characterise the material.
Characterise its behaviour in a non-linear regime in -50°C to 120°C.
Generate material models to be implemented into simulation and final component validation campaigns.
The Validation Platform demonstrated that out of 700 tests performed, only 70 were needed for full understanding and trust of the material.
A 10x reduction in experiments to fully characterise the material, compared to conventional, manual strategies.
The data congruence tool harmonised the figures of merit and tolerances in historic and current data. Fitting this data to material models took seconds as opposed to hours.
A 1000x reduction in time to process and fit data to material models.
The quality management tool produced quantified uncertainties.
The end user understands the level of trust in the material model
In total we reduced the time and cost of the project by >10x.
A Paradigm Shift.
Accelerating the mass adoption of new and emerging manufacture processes and materials such as additive manufacture, fibre composites and recycled materials is key for Industry 4.0.
The Synbiosys Validation Platform is a deep tech AI software tool that targets the main bottleneck:
We enable you to quickly and cost-effectively achieve trust, validation and sign-off of components manufactured by these next generation technologies.
We help reduce the pyramid of tests, total resources and workload required for the sign-off of critical components by a factor of 100x.
In 1797 Henry Maudslay revealed his screw cutting lathe to the world, an invention that revolutionised the manufacturing industry. He enabled both the repeatability of the manufacturing process and the standardisation of screw threads - key factors in enabling interchangeability of parts. He is credited as the father of the machine tool industry and one of the key enablers of both the first the second industrial revolution.
Fast forward 200 years, our materials and manufacturing processes have progressed significantly.
However - Our process of obtaining trust in components made from these emerging methods has not.
Industry 4.0 is currently impossible because we are treating 21st century materials and manufacturing processes with 19th century methodologies. The world has not harnessed the true potential of advanced manufactured parts not because of the materials, but because of how we think about them.
With large and complex manufacturing parameter spaces, a fresh look at repeatability and standardisation is required to unlock their full potential.
Contact us for our white paper on how our AI-driven Validation Platform enables the rapid trust and validation of new and emerging materials and manufacturing processes.
The Keys to Industry 4.0
Whether you are using advanced additive manufacturing technologies to make cutting edge one-off components for the space industry or mass producing consumer goods from recycled feedstock, Synbiosys' Validation Platform can reduce the associated costs and time to market by 100x.
The Validation Platform helps you arrive at the correct production 'recipe' faster and provides an optimised quality management strategy for mass production.
The Validation Platform has applications across all engineering and manufacturing industries including: Aerospace, Automotive, Space, Defence, Renewables & Energy, Consumer Goods and Recycling.
The Next Industrial
“I can buy 2 identical 3D printers, ask them to print the identical design, and I’ll get 2 different components”
Unlike more traditional manufacturing processes, in AM the material, manufacturing process and component are inherently intertwined. This increases complexity by orders of magnitude. Current approaches to validate and trust AM components is to brute force the characterisation of the full manufacturing parameter space.
This costs years and millions of dollars per part.
This is economically unfeasible and prevents industry-wide adoption.
The Validation Platform navigates through the parameter space, reaching the confidence levels needed to validate a part 100x faster than current methods.
We need everything lighter, stronger, faster, bigger, and greener to meet the challenges of tomorrow.
Fibre composites are earmarked to play a pivotal role, with the potential to use fast and scalable manufacturing processes.
The challenge - Fibre composite manufacturing is currently more of an art form. We need to move towards fully automated, validated manufacturing techniques.
The Validation Platform identifies and quantifies the interdependencies between the many interlinking parameters, and provides confidence levels to variations and tolerances in an automated manufacturing process.
This paves the way to adoption and easier standardisation of next generation composites, including biodegradable feedstock and resins, with full automation of fibre composite manufacture.
The push for having over 30% recycled feedstock in packaging gives rise to an unsolved issue: How do you manufacture a consistent end product when the feedstock composition changes daily and unpredictably?
With performance like virgin plastics but not touched for the very first time - our Validation Platform allows for accurate and quick predictions of the properties of an end product made from highly variable recycled feedstocks.
The Validation Platform enables trust both in the final product and in the manufacturing process, allowing for the adoption of plastics with high recycled content in safety and performance critical applications.
Living in a Material World.