For example, we worked on a customer
project requiring a solution for outboard
motors used on a rigid inflatable craft. The
core challenge stemmed from a health
and safety perspective and the need for
a lighter outboard motor that could be
safely and more rapidly lifted on and off
the craft by two people. By using high
strength forged carbon fibre to replace the
traditional aluminium, we were able to meet
the challenge and deliver a 12kg weight
reduction.
MEDICAL LIFESAVERS
In the medical sector, one of the major
challenges is meeting the demand for
aids that help overcome the ever growing
pressures of the population demographics
and the impact this has on healthcare
providers. Therefore the equipment needs
to provide faster, more accurate and easier-
to-manage ways for the care professionals
to do their jobs.
In surgical robotics for example, we’ve
been working with a company leading the
way in equipment that’s significantly lighter
than traditional alternatives. It can be easily
moved around operating theatres and
hospitals providing surgeons with a lighter
weight robotic arm that’s easier to control
and is lighter and easier to handle as
smaller motors are needed. It means more
operations, increased value of investment,
increased accuracy and more saved lives.
DRIVING ECONOMY MAKES NEWS
One of our projects that attracted
international headlines at the end of last
year was a collaboration with the engineers
of tomorrow studying at Cambridge
University. We helped them create a cutting
edge car weighing only 550kg by using an
ultra lightweight carbon fibre chassis so it
could go further and faster than would be
possible using other materials.
It has earned its place as one of the
world’s most energy efficient solar cars
able to travel at 50mph from London to
the Scottish Highlands on the same power
it takes to boil a kettle. It competed in the
epic 3000km Bridgestone World Solar
Challenge race across Australia, collecting
interest from the engineering community
and the international media.
THE KNOCK ON EFFECT FOR OIL
AND GAS
Savings of millions of pounds can be
achieved by embracing the lightweighting
principle in the oil and gas sectors with
real long term benefits. Metal pipes
can become so long and heavy that
they cannot support their own weight
and therefore a heavy rig is needed for
support. By taking weight out of the pipe
using the latest composite technologies,
smaller installation ships are needed with
the knock-on savings running into the
millions.
Carbon fibre offers huge
design scope.
THERE’S LIGHT FOR THE FUTURE
The opportunities for lightweighting are
everywhere and the designs of the future
across all manufacturing sectors can make
huge all-round improvements. While the
benefits for lowering the carbon footprint
are well known, for those seeking to make
products that are easier and safer for people
to use by being smaller and lighter, it all
contributes to bigger picture savings.
For those ready to open up their
imaginations to the possibilities it needn’t
be intimidating. Choosing the right partner
who already understands the concepts
and possibilities across sectors can help
to leapfrog the inevitable lightweighting
learning curve, with endless opportunities
ready to be grasped.
REF: https://www.mckinsey.com/~/
media/mckinsey/dotcom/client_service/
automotive%20and%20assembly/pdfs/
lightweight_heavy_impact.ashx
For further information, please visit www.formaplex.com
Issue 44 PECM
7