MATERIALS IN DESIGN & PROTOTYPING


PROJECT MAKES THE WORLD’S MOST EXPENSIVE METAL VIABLE FOR ADDITIVE MANUFACTURING


Cookson Industrial provides consultancy, R&D, NPD and production, helping revolutionise the industrial use of precious metals such as gold, silver and platinum. Its metallurgists and engineers design and develop wire, sheet, grain, sputtering targets, brazing alloys and atomised powder for industries ranging from aerospace and automotive to medical and glass fibre manufacturing. When rhodium is used as an alloying agent for hardening and improving the corrosion resistance of platinum, the outcome is a new material known as platinum rhodium. Used in some of the most demanding applications, including furnace windings and bushings for glass fibre production, this is the only commercially available metal that can withstand the high temperature and corrosive environment of molten glass. For this reason, Cookson Industrial intended to use platinum rhodium to 3D print an extrusion mould designed for glass fibre manufacturing. However, platinum rhodium is one of the world’s most expensive metals. Wanting to keep waste to a minimum, the company chose a RenAM 500S Flex additive manufacturing (AM) system from Renishaw. Equipped with an open-loop powder system enabling quick and easy powder swapping, the system speeds up the qualification of material properties, part design and process parameters. The powder management system is designed for external sieving, which allows for greater flexibility in selecting powders. Initial tests showed the system was already capable of achieving a low powder loss of less


than 1.5%, but the company wanted to reduce this to less than 0.5%. So, Renishaw worked with Cookson Industrial’s engineers to identify ‘powder traps’ and then embarked on a fast-paced schedule of re-designing and re-testing system components to maximise powder retrieval. The customisation process included removing parts where small amounts of powder can


accumulate, including overflow bellows and the rear overflow vent system. Renishaw further optimised chamber design to prevent any powder loss during the depowdering process. The company also designed special casings and covers for the lower chamber, powder flask chamber and filter cabinet, to eliminate any other potential powder traps. The customisation process was a success, enabling the RenAM 500S Flex to reduce the wastage of platinum rhodium powder beyond expectations. The AM machine saw a staggering 95% reduction in trapped powder, allowing Cookson Industrial to minimise losses and retrieve the equivalent of a teaspoon of powder per cycle – a saving of around £1000. “Renishaw’s technology and expertise were


critical to the success of this important R&D project, paving the way for scalable production of high-value platinum rhodium parts across a range of applications,” commented Nikesh Patel, head of Cookson Industrial. Cookson Industrial is now planning to use platinum rhodium in applications such as catalysts and aerospace engine nozzles.


Renishaw www.renishaw.com


PROTEIN-BASED AIRCRAFT SEAT BIOFOAM OFFERS ‘EXCEPTIONAL ERGONOMIC PERFORMANCE’


Muirhead, a global leader in high-performance aviation leather, has unveiled its pioneering BioPRO Foam – the world’s first naturally fire-resistant, protein-based, aviation biofoam. The patented innovation is made with hydrolysed collagen, a by-product of Muirhead’s own leather manufacturing process. With 20% bio-content, it eliminates concerning substances such as melamine and PFAS (‘forever chemicals’) found in traditional seat foams, resulting in enhanced fire safety, durability and passenger comfort, as well as offering clear environmental benefits. By combining leather seat covers and BioPRO cushions, Muirhead now delivers a seamless,


one-stop seating solution with consistent aesthetics and precise dimensions. Muirhead chemically bonds collagen to the foam chemistry, resulting in a seat foam that is


stronger, more durable, and intumescent. This process ensures the bio-content becomes a functioning part of the foam, eliminating internal abrasion and expanding its lifespan. The product is designed to adapt, providing targeted support for different body types. Independent testing confirms its exceptional ergonomic performance, ensuring a superior seating experience for a diverse range of passengers. While traditional foams are cut from large blocks, BioPRO is moulded to the customer’s precise specifications, an approach which eliminates waste and offers complete customisation for airlines, seat OEMs and airframe manufacturers. The moulded cushions ensure consistent shape and size, guaranteeing uniform aesthetics throughout the cabin.


Muirhead www.muirhead.co.uk/en


PRODUCTS


SUSTAINABLE FLAX COMPOSITES FOR THE AUTOMOTIVE INDUSTRY


A new collaboration between Bcomp and SFG Composites will bring flax fibre composites to the automotive industry. This high-performance, lightweight and eco-friendly material offers an alternative to traditional plastic, glass and carbon fibre-based materials, helping drive the transition towards more sustainable vehicle production. Bcomp’s ampliTex and powerRibs flax fibre


technologies are said to offer exceptional strength-to- weight ratio, superior vibration damping, and


significant CO2 reduction, making them an ideal choice for interior and structural applications. High performance bio-based materials also offer new possibilities in automotive interior aesthetics with enhanced cosmetic options and mechanical properties that are sustainable by nature. The company’s natural fibre composites are already used by industry leaders such as BMW Motorsport, Volvo and CUPRA. SFG Composites will integrate Bcomp’s flax


fibre reinforcements into its compressed moulded technology and manufacturing processes. Flax fibre composites provide an outstanding


balance of weight reduction, safety and durability, crucial factors in next-generation vehicle design. Compared to traditional materials, they offer: • Reduced weight by up to 50% vs. similar plastic parts, with equivalent performance, improving fuel efficiency and EV battery range


• Up to 60% lower CO2 footprint vs. similar plastic parts


• Increased safety performance with no sharp edges • Enhanced vibration damping for ride comfort • Circular opportunities for large-scale industries including for inevitable scrap that can be recycled into a new base material • A full new range of sustainable design possibilities by using woven and non-woven natural fibres to fit the unique language of every brand


• Seamless integration into existing automotive processes, from one-step back-injection to compression moulding. “Automakers worldwide are looking for innovative


ways to reduce their environmental impact without compromising on performance,” commented Johann Wacht, manager business development & strategic customer relationships at Bcomp. “Through this collaboration with SFG Composites, we can scale the adoption of natural fibre composites, providing a lightweight, high-performance solution that meets the needs of modern mobility.”


Bcomp www.bcomp.com


MARCH 2025 DESIGN SOLUTIONS 55


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