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New and Emerging Technologies – Materials and Components

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Learning outcomesStudents should be able to: • discuss the impact of new and emerging technologies on the design and manufacture of products in

relation to: – the materials and components; – recycling; – environmental costs; – reduced energy costs; and – maintenance and repair.

FACTFILE:GCSE Engineering and Manufacturing3.3.6 New and Emerging Technologies – Materials and Components

Materials and componentsIn order to stay competitive in ever changing markets every manufacturing organisation will explore means to improve their product and to reduce the cost of their products in order to hold on to, and expand their share of the market. Production management and research and development teams will look to emerging technologies to take advantage of these in as many aspects of the production process as possible.

Virtual product testingWith increasing pressure on manufacturers to reduce the product development time and costs, some are creating a new trend in engineering outsourcing, which mainly includes computer aided simulations for product testing. There is a shift in offshore work that also consists of virtual product testing through simulation tools.

Research shows that outsourcing virtual product testing activities significantly helps in reducing the product development costs as there is no special need of setting up the infrastructure and hiring skilled professionals.

Some of the other benefits of outsourcing these activities include:• access to global talent pool to help in product

innovation;• value addition to build better products at low

cost;• reduction in time-to-market; and• extending the organisation’s capability with less

investment.

These cost saving benefits are further enhanced when teamed with the possibility of using 3-D printing which allows for speedy prototyping and producing cheaper objects, with the potential to customize products for individual consumers, such as, buildings, cars and electronic devices.

Additive layer manufacturingRapid prototyping is used to quickly fabricate a scale model of a physical part or assembly using three dimensional computer aided design (CAD) data. Construction of the part or assembly is usually done using 3D printing or additive layer manufacturing technology which are used for a wide range of applications and are used to manufacture production quality parts in relatively

FACTFILE: GCE HISTORY OF ART / ARCHITECTUREFACTFILE: GCSE ENGINEERING AND MANUFACTURING / 3.3.6

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small numbers if desired without the usual disadvantages of short run economics.

Combined with internet technology and outsourcing virtual product testing, 3D printing would allow for digital blueprints of virtually any material product to be sent instantly to another person to be produced on the spot, making purchasing a product online almost instantaneous.

There are further cost savings benefits for the manufacturer as the name suggests, additive manufacturing is the opposite of subtractive manufacturing. Subtractive manufacturing is how manufacturing has traditionally been done: starting with a larger piece of material (wood, metal, or plastics), layers are removed, or subtracted, to leave the desired finished product. Additive manufacturing instead starts with loose material, either liquid or powder, and then builds it into a three-dimensional shape using a digital template.

An important next stage in additive manufacturing would be the 3D printing of integrated electronic components, such as circuit boards. Some computer parts, like processors, are difficult to manufacture this way because of the challenges of combining electronic components. 4D printing now promises to bring in a new generation of products that can alter themselves in response to environmental changes, such as heat and humidity.

AI (artificial intelligence)Manufacturing has come a long way since the 1960s, when the first industrial robot made its debut at General Motors. But the early industrial robots were essentially machines that could only perform a single task. Now, industry is in the first stages of its next automation breakthrough, using artificial intelligence, or AI, to make production decisions in real time.

Applying AI to manufacturing requires a number of key, basic technologies and process innovations. A smart factory is a networked factory, in which data from supply chains, design teams, production lines and quality control are linked to form an integrated, intelligent production engine.

The ideal intelligent factory operates along the following lines;• software captures order data from customers;• the software automatically orders production on

new units; – if an entirely new part is needed, the order is sent to design teams,

– using 3D printing technologies, they can; – design, – prototype and – test a new part in hours instead of days or weeks.

• the part then goes into production on a line staffed by AI robots,

– each stage is monitored by sensors; – data is fed to AI and analytics software; – if a defect is spotted, or a new part is needed the software orders the part and the process begins again.

Industrial and consumer product companies are trying to keep their manufacturing costs as lean as possible to increase profitability, and want to keep stock only on an as-needed basis. AI offers problem solving in real time that can save manufacturers millions of pounds in recalls, repairs and lost business.

GrapheneOne of the most exciting developments in materials technology is the rise of the use of graphene. Graphene is an atomic scale honeycomb lattice made of carbon and is emerging as one of the most


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promising nanomaterials because of its unique combination of properties, which opens a way for its use in a wide range of applications ranging from electronics to optics.

In manufacturing graphene is best suited to:• components with higher strength to weight ratios;• transistors that operate at higher frequency;• display screens in mobile devices;• storing hydrogen for fuel cell powered cars;• sensors to diagnose diseases; and• more efficient batteries.

RecyclingThe UK Government’s Department for Business, Energy and Industrial Strategy states in it’s 2016 strategic review that by 2030 “products and processes will be sustainable, with built in reuse, remanufacturing and recycling for products reaching the end of their useful lives. Closed loop systems will be used to eliminate energy and water waste and to recycle physical waste”.

This reinforces the fact that the Earth’s natural resources are limited and to achieve sustainable development, we need to balance the following issues carefully:• the need for economic development;• improving standards of living; and • respect for the environment and it’s resources.

Recycling is an important way to help us achieve sustainable development. We can recycle many resources, including:• glass;• metal; and• paper.

Glass is easily recycled. It can be melted and remoulded to make new objects, such as bottles. As with glass, it takes less energy to melt and remould metals than it does to extract new metals from their ores. However, this simplicity is not mirrored in the recycling of plastics. For example, more than 250,000 mobile devices are discarded every day worldwide. Recycling programs exist but as few as 10% of phones are recycled, the rest are doomed to be waste in landfill sites. The issue with the devices is that they contain thermoset plastics as opposed to the recyclable thermoplastics family.

The UK has a plastic packaging recycling target of 57% by 2020, turning waste into a new substance or product.

There are many benefits to be gained by the responsible recycling of plastics:• provides a sustainable source of raw materials to

industry;• greatly reduces the environmental impact of

plastic-rich products;• minimises the amount of plastic being sent to the

UK’s diminishing landfill sites;• consumes less energy than producing new, virgin

polymer;• avoids the consumption of the Earth’s oil stocks;

and• encourages a sustainable lifestyle among

children and young adults.

In the last ten years the manufacturing industry has focused on minimising waste in the production stages and being more efficient in the use of resources. As a result of this, the industry has seen a great decrease in the tonnage of plastic waste created as off-cuts or surplus scrap. A growing number of large modern manufacturing sites now operate onsite recycling facilities in order to reduce the amount of valuable materials which would otherwise be disposed of as waste.

Of the 5 million tonnes of plastics used per year almost 50% is packaging. 1.7 million tonnes come from households and the rest from commercial and industrial companies. Items such as plastic bottles, pots, tubs, trays, and plastic bags are the most common types of household plastic waste. The commercial and industrial packaging waste streams are largely made up of stretch-wrap films, which are often used to cover goods during shipping and returnable transit packaging such as pallets, crates and drums.


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First recyclable thermoset plastics producedCalifornian scientists have created the ‘first’ thermoset plastics that are completely recyclable successfully demonstrating a new class of polymer that is ‘resistant to cracking, stronger than bone, can reform to its original shape, and is completely recyclable.

Although yet to be developed for commercial purposes, it is hoped the new polymer (known as PHTs) could ‘transform manufacturing and fabrication in the fields of transportation, aerospace, and microelectronics’. This is a major step forward in the quest for greater recycling of plastic products.

Environmental costsIt is now generally accepted that the increase in carbon dioxide in the atmosphere is a cause of global warming. It has taken a long time for this to be fully accepted as there has been uncertainty in some of the data. As more data has been collected the degree of scepticism has declined. Computer models help us to predict that an increase of only a few degrees will cause changes to the Earth’s climate. This is why it is important to attempt to combat global warming, for example by reducing our reliance on fossil fuels. Carbon dioxide is produced by burning fossil fuels and because of this, the amount of carbon dioxide in the atmosphere has increased, especially in the last one hundred years.

Carbon dioxide is a greenhouse gas. It absorbs heat energy and prevents it escaping into space. This keeps the Earth warm enough for liquid water and living things to exist on it. Greenhouse gases are not a bad thing in themselves, but too much of them in the atmosphere leads to global warming, where the average temperature of the Earth rises quickly.

Designers and manufacturers have an important role to play in the research and development of the techniques listed below which could be vital to protecting the environment:• cleaner generation of coal fired electricity, with

advanced technologies being used, • renewable energy technologies such as:

– offshore and onshore wind power; – wave energy; – tidal energy; – biomass;and – solar energy increases the supply of clean energy.

• electric vehicles, biofuels and other emerging low carbon technologies change the face of transport; and

• hydrogen starts to have an impact as an energy carrier, in the transport, domestic and other sectors.

Fourth generation nuclear reactors and nuclear waste recyclingCurrent nuclear power reactors use only 1% of the potential energy available in uranium, leaving the rest radioactively contaminated as nuclear “waste”. As the political debates surrounding nuclear waste limit the appeal of this zero carbon energy technology fourth generation technologies, including liquid metal-cooled fast reactors, are now being deployed in several countries.

Reduced energy costsProduction has its costs be it direct costs in terms of workforce and materials, indirect costs such as administrative staff and research and development, or manufacturing overheads including power costs. If a manufacturer can reduce any of these elements, then they can be more competitive in the business place. How can a company achieve this in terms of energy costs?


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There are a number of strategies which can lead to such a reduction which includes:• Developing an Energy Management Team

– One of the primary reasons energy and cost-saving initiatives fail is because it is unclear whose responsibility it is to manage the undertaking. By developing an energy management team, it is possible to monitor energy usage and implement ways to reduce waste.

• Conduct an Energy Audit – A useful energy audit will quantify how much energy each department is consuming and will help identify peak consumption times throughout the year. It should also offer recommendations on which energy efficiency upgrades will bring the best return on investment.

• Strategically Schedule Machinery Use – Using the data collected from the energy audit, it will be possible to identify which machinery requires the most energy to run. If possible, schedule operation of these machines outside of peak hours which can cost up to 30% of a manufacturer’s monthly utility bill.

• Optimise Air Compressors – Industrial air compressors are to blame for huge amounts of energy consumption and waste. Some are poorly designed, while others are improperly maintained. A targeted maintenance programme will significantly reduce these losses and reduce energy costs.

It will also benefit manufacturers to investigate the benefits of switching to renewable energies to be their primary source of power. Renewable energy technologies such as solar energy, onshore wind power and biomass could all benefit the manufacturer by reducing costs. The use of biofuels, electric vehicles and other emerging low carbon technologies change the face of transportation of the finished products and create further production savings.

Maintenance and repairIn modern manufacturing plants the production process will only be productive and profitable whenever the plant is working. If one element of the production process fails it can lead to the production coming to a complete standstill.Preventive maintenance is one of the key strategies to keeping the manufacturing process running

smoothly. However, preventive maintenance is only one type of maintenance that should be part of a company’s overall strategy, including:• preventive maintenance;• predictive maintenance; and• reactive maintenance. If preventive maintenance is used in conjunction with a predictive and reactive maintenance strategy, costs can be controlled while maximising production.

The development of modern remote monitoring technology enables instant access to data from equipment on the production line. While this technology is able to reduce operating expense, it also brings other benefits. By being able to have full control 24/7 and be instantly notified of any operational issues, the manufacturer also receives improved service quality.

There are three main elements to a modern remote monitoring solution which are:• a communication system that;

– links to the equipment, – acquires the data, and – communicates it to the remote server.

• a remote server that collects and stores the data; – referred to as “The Cloud” and is basically a server on the internet.

• the software services that provide secure access to the data;

– includes functionality such as SMS or Email alarms.

With a remote management solution, operating hours, oil pressure, battery status, fuel levels etc. can all be checked online. A notification may also be generated whenever a critical level has been reached.

As the use of industrial manufacturing robots has increased it is important that they have an efficient maintenance programme to keep them working at full capacity. Maintenance and diagnostic programmes are important in keeping industrial robots at their optimal operating performance. By simply cleaning and lubricating robots periodically, this can go some of the way to achieving peak performance, but with controls built into them, this can provide a preventive maintenance capability as well as the ability to diagnose problems. The trend in developing robotic diagnostics and maintenance allows for more software integration packages to


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be installed in these robots that will help diagnose problems and potential failures to prevent a break in production.

Smart robots have this facility to recognise, report and remedy faults as they present themselves which reduces the risk of their failure within

the production process. The expansion in their usage across manufacturing plants will lead to an improved level of reliability, managed maintenance, reduced downtime and a reduction in production costs.


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Revision Questions1. Give three advantages of virtual product testing to the manufacturer.

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_____________________________________________________________________________________ 2. Describe briefly how 3D printing works.

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3. How can 3D printing reduce material costs?

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4. What aspect of AI (artificial intelligence) is most beneficial to the manufacturer?

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5. List three areas to which graphene is best suited.

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© CCEA 2019

6. List some of the benefits gained by recycling plastics.

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7. What is the biggest source of waste plastic?

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8. What is the main cause of carbon dioxide in the atmosphere?

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9. List three sources of renewable energy.

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10. What are the elements involved in remote monitoring?

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Additional resourceshttps://www.gov.uk/government/publications/future-of-manufacturing/ https://www.brookings.edu/wp-content/uploads/2016/06/robotwork.pdfhttp://www.dailycadcam.com/computer-aided-engineeringwww.physics.org/article-questions.asp?id=67https://www.eef.org.uk/campaigning/http://www.plantengineering.com plant/072d9c949aba95cf2caf8f6d2f3dac64.htmlhttps://mitpress.mit.edu/books/artificial-intelligence-applications-manufacturinghttp://www.maintworld.com/Asset-Management

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