Aerospace Sensing Technology Could Lead to Transformation of UK Industry

A groundbreaking sensing technology developed by researchers at the University of Bristol could revolutionize the UK manufacturing industry, particularly in fields such as aerospace. The study, published in the journal Waves in Random and Complex Media, introduces a formula that can determine the design boundaries for components’ geometry and material microstructure.

Currently, there is a lack of commercially viable sensing technology to assess the quality of components, especially in additive manufacturing (3D printing) of metallic parts. However, the use of ultrasonic array sensors, similar to those used in medical imaging, could provide a solution without the need for direct contact with the material.

Professor Anthony Mulholland, the head of the School of Engineering Maths and Technology, explained that the team’s mathematical model incorporates the physics of ultrasonic waves propagating through layered metallic materials, accounting for variability between each component. This formula, based on design parameters and material characteristics, can optimize the information produced by the sensor to evaluate mechanical integrity.

The researchers aim to collaborate with industry partners to deploy laser-based ultrasonic arrays in additive manufacturing environments, enhancing production processes and ensuring safety standards. By generating tomographic images of components’ interiors, they can assess quality without destructive means, potentially opening up new design possibilities and economic advantages for UK manufacturing.

Professor Mulholland emphasized the significance of this technology in advancing 3D printing for safety-critical components, highlighting the potential commercial benefits for the aerospace industry. The team’s innovative approach could accelerate the deployment of this solution, paving the way for a new era of manufacturing excellence in the UK.