Cutting edge: Reform project reduces costs and environmental impact of composites

The REFORM project focused on the forming, machining, assembly and recycling of composites.

The University of Sheffield Advanced Manufacturing Research Centre (AMRC) with Boeing coordinated the €7m (£5.5m) four-year project and led research into waterjet cutting and milling of composite components.

Waterjets use high-pressure water containing abrasive particles to erode materials, effectively cutting them.

AMRC designed a new cutting head and a small nozzle to increase accuracy and cutting power. CAM modules were created to optimise cutting and milling parameters.

REFORM coordinator Dr Rosemary Gault, from the AMRC, said: “Manufacturing the new cutting head was really difficult. We did the design quite early on before we figured out how to actually make it.”

“It’s all about the geometry and the assembly, to assemble all the bits together so that it doesn’t all fly apart when the high pressure water goes through it,” she added.

The research resulted in up to 95 per cent recovery of water and abrasives, a reduction of up to 75 per cent in machine and delivery times, and less scrap.