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A revolution in manufacturing that has the potential to transform industry worldwide has arrived. The pioneering technique known as additive manufacturing is still being perfected, but its advantages are already being exploited commercially by big business.

The unique characteristics of additive manufacturing are behind Loughborough University’s £2.9 million ATKINS project, which aims to reduce waste, weight and CO2 emissions in the automotive and aeronautical sectors.

The University is recognised as the world’s leading research group in this field. Alison Laing met Professor Richard Hague, Head of the Additive Manufacturing Research Group (AMRG), to discuss the emerging key technology, and its impact on the innovative ATKINS project.

Additive manufacturing builds products by using electronic data rather than traditional factory tools and methods. It works by breaking down a 3D computer- aided-design (CAD) model into 2D digital sections, which are then built up layer-by- layer by high-tech machines – effectively, directly 3D-printing the required design.

These manufacturing techniques, specifically Selective Laser Melting (SLM) of metallic components, are being applied to make lightweight parts for aircraft and motor vehicles. It’s called the ATKINS project, and its purpose is to ensure the design, manufacture and distribution of components are more sustainable, with a significantly reduced carbon footprint.

“A 50 percent weight saving in components ensures much less fuel is needed, which means less greenhouse gas emissions over the whole product life cycle”

A team of academics at Loughborough – Professor Richard Hague, Dr Chris Tuck, Dr Ricky Wildman and Dr Ian Ashcroft – are working on the three-year project. The multi million pound venture is a collaboration funded by the UK Government and a consortium of industry partners, including Boeing, Virgin Atlantic, Delphi, MTT and Bentley Motors.

Professor Hague said: “I have never worked on a project where there has been such enthusiasm from industry partners. It’s been phenomenal.

“There is great excitement about ATKINS and its potential as a future key technology. The benefits for consumers, industry and the environment are staggering.”