Really excited to announce the latest Doctor from the RDF team - Dr Neil Wilson. Neil combined his PhD with being the chairman of a highly innovative SME- Romar Engineering and his doctorate highlights how to use advanced learning technologies - Evolutionary Algorithms to drive innovation in manufacturing
🎓 Excited to share insights from my PhD journey! 🌐
Title: "Techno-economic analysis of conformal tooling via hybrid manufacturing"
🔍 Thesis Abstract:
Injection moulding, a cornerstone in polymer manufacturing, thrives on efficiency. However, the traditional design of injection moulding tools often results in costly redesigns post-prototype testing. My research introduces a groundbreaking generative design approach to tooling, specifically focusing on Conformal Cooling Channels (CCCs). These 'smart' CCCs, crucial for optimal performance, are crafted using a novel combination of evolution-based optimisation and iterative routing methods.
🌟 Major Innovation:
The application of generative design in Injection Moulding (IM) tooling has yielded a tool capable of reducing cooling times by up to 50%, a game-changer for part consistency, accuracy, and manufacturing cycle time.
💡 Implications:
To bring these advanced designs to life, I explored Hybrid Manufacturing (HM), a fusion of additive and subtractive technologies. This approach not only enhances productivity but also meets the manufacturing requirements of complex geometries.
🔄 GD + HM = Substantial Benefits:
The synergy between generative design and hybrid manufacturing promises significant returns on investment for IM tool designs. The economic assessment of the sample part reveals a minimum of 80,000 moulded parts is required to offset the higher costs of hybrid manufacturing, with a predicted 127% ROI within a year for producing 100,000 parts annually.
🌐 Impact on Australian Manufacturing:
With high labour and manufacturing costs in Australia, the proposed methodology offers a cost-effective solution, potentially revolutionising the tool design and manufacturing landscape.
📈 Next Steps:
As I embark on raising the profile of Romar Engineering, I'm eager to explore commercial and academic collaborations. Let's connect to discuss the transformative potential of my research in advancing injection moulding technology! 🤝
#PhDInnovation #InjectionMoulding #GenerativeDesign #HybridManufacturing #Tooling #EngineeringExcellence