Printable sensors set to ensure faster and more reliable manufacturing processes

Faster and more reliable manufacturing processes, with less human intervention, should be possible thanks to a UK collaboration to develop printable sensors for monitoring machined metal parts.

The two-year Innovate UK-funded project, called Intelligent Tooling, will develop sensors and electronic components that can be embedded close to the cutting surface of the tooling inserts in machining systems, to monitor the manufacturing process in real-time.

The sensors will be designed to monitor a range of parameters during machining, such as temperature, force, acoustic emission and vibration, meaning any small changes can be spotted and dealt with immediately.

This should improve processing times and tool usage, according to Steven Bagshaw, business development at the Centre for Process Innovation (CPI), one of the partners in the project.

“This allows you to identify early stage deterioration of tool insert performance,” he said.

A lack of real-time monitoring in existing machining means variations in material or tooling properties, for example, are often only detected in the final product inspection.