The I-Form Research Centre for Advanced Manufacturing, financed by Science Foundation Ireland, collaborates with the industrial sector to delve deeper into the complexities of manufacturing processes and the digital tools required for their optimisation. Their primary aim is to revolutionise the future of manufacturing by conducting high-impact research on the use of digital technologies in materials processing. This collaboration facilitates the innovative, low-cost design of new products and the production of high-value components with improved material performance. Simultaneously, it allows for a reduction in processing times and enhanced process reliability.
The Centre’s director, Professor Denis Dowling, elaborates on their role: “We conduct research in advanced manufacturing which covers a broad range. We concentrate on the digitalisation of materials processing. Utilising various digital tools enables us to monitor activities when a material is transformed from one state to another or during the fabrication of a product which requires melting metal or a polymer. It affords us the ability to offer real-time feedback to the operator thereby enabling us to optimise both the process and processing conditions.”
This methodology involves the integration of Internet of Things (IoT) technology and sensors to collect and analyse data. As Dowling explains, they are able to utilise machine learning to gain a fundamentally deeper understanding of various processes.
Accumulated experience paired with real-time data allows more precise and useful interpretations. All efforts are channelled towards making manufacturing processes more efficient and sustainable, Dowling says.
He further adds, “Ireland ranks second in Europe for medical device manufacturing. Mostly, device fabrication begins with a metal, frequently in powder form. Its transformation into a specific shape requires a comprehensive knowledge of the process and processing conditions. Knowing how the product and the material will react during the transformation allows for optimisation when fabricating the medical device.”
Dowling illustrates the significance and potential of this understanding by explaining how real-time monitoring can help eliminate anomalies in the process: “Timely interventions can save a process run if you see a process veering off specification. If you can identify altered conditions a third of the way through, you can terminate the run. The efficiency of the process can be greatly increased by using digital tools that keep us informed about what’s happening.”
The utilisation of modern technologies such as machine learning is offering significant support. Dowling states, “With the rapid functioning of the models, we are entering a phase where there is a strong potential for comprehensive optimisation of processing conditions, yielding savings on materials and energy consumption.”
In the current scenario of escalating scarcity of raw materials, Dan emphasizes, “If we continue our current consumption trends, we would require resources from multiple planets to meet our needs. Hence, it’s imperative that we implement higher efficiency and sustainability in our utilisation of materials.” The recycled materials may have potential impurities and understanding their potential impact on performance is essential.
“The material that was originally part of a medical appliance might serve different purposes later. In additive manufacturing, a material can be reused often, but to what extent? What alterations occur in their properties?” He further states the importance of understanding the elemental composition, material chemistry, and the mechanical performance of the material.
According to Dowling, these are areas demanding research. “The mechanical performance could be forecasted through modelling. One of the firms has informed us that our models have facilitated a 90% reduction in their experiments.”
The application of AI is poised to revolutionise the manufacturing industry, as per Dowling. “AI could give you a competitive edge by optimising the processing or process conditions,” he discloses. “Ireland must be proficient in AI in order to survive in this competitive world. I-Form assists companies to adopt AI strategies and technologies, ensuring Ireland maintains its leading status in the advanced manufacturing sector.”
The quality of the I-Form graduates has robust national significance. “To date, over 130 PhD scholars and postdoctoral researchers have graduated,” boasts Dowling. “Their profound understanding of manufacturing, materials and digital tools combined with their skills is a significant advantage to the advanced manufacturing industry.”
Such skills will position Ireland favourably in attracting future Foreign Direct Investments (FDI). “Ireland’s edge is largely attributed to the tax protocol, which is currently being revised,” Dowling warns. “A global minimal tax rate is emerging. The US Inflation Reduction Act is investing $369 billion in specific sectors. The European Chips Act is investing €43 billion in semiconductor manufacturing. Ireland has benefited significantly from FDI over time. However, other countries are now emulating the Irish model. The sole long-term competitive factor will be human talent and skills.”
The person highlights that Ireland’s contribution to Research and Development (R&D) is disappointingly low in comparison to other European countries – even trailing behind Hungary when based on gross national income, a figure that is typically lesser than GDP. He insists that the country needs to produce a strong pool of skilled individuals for the future.
Drawing attention to Ireland’s past, he notes how investments in education since the 1960s have allowed businesses to thrive in the country. However, in recent times, the funds directed towards education are not at par with the European average. Considering this from a competition standpoint, he indicates that this could have a delayed impact and thus, affect the country in the long run.
The person urges to be proactive and adaptable in dealing with this issue. He emphasises that the country must focus on human resources and research facilities as these are crucial for attracting Foreign Direct Investment (FDI) in the future.