Research Areas

Optical metrology covers a broad array of techniques and technologies which utilise the properties of light to carry out measurements of important parameters in manufacturing such as distance, shape and surface texture. In general, optical measurement has the advantages of not requiring mechanical contact with the measurand, being relatively fast, and able to operate over wide range and resolution. The CPT is researching new optical measurement principles based on novel technologies in order to try and realise instrumentation that is better suited to in-situ measurements, where sensors are integrated into manufacturing processes. This requires combining the latest optical technologies (e.g. light sources, sensors) and emerging physics (e.g. metasurfaces, quantum sensing) to reduce the size of optical instrumentation while at the same time enhancing its functionality in a variety of ways. 

Surface finish, quality and functionality are critical factors in many areas of engineering. The CPT has extensive capabilities to characterise and measure surfaces for both research and commercial purposes. These include both contact and non-contact measurement systems, surface replication and modelling, as well as  X-Ray Computed Tomography (XCT). We cover wide areas of application from aerospace to bio-implants  and from ultra smooth surfaces to rough surfaces such as those produced by additive manufacturing. 

Ultra-precision manufacturing covers a wide range of techniques used in the creation of parts with super finished surfaces or which incorporate micro and nano scale geometries. The CPT facilities include state-of-the-art machining centres capable of diamond turning and grinding with additional capacity for slow and fast tool servo control and in-process tool/workpiece monitoring. 

Advanced mathematical analysis and data handling techniques are a necessary accompaniment to advances in metrology technology which rapidly gather vast quantities of data. The ability to process and use this data in real time can only be accomplished through computational methods. The CPT team work to develop new approaches to data handling and the associated mathematical languages and standards.  

There is a direct correlation between the success of a manufacturing company and the performance of its machinery. Here at the Centre for Precision Technologies, we pride ourselves on being experts in performance assessment of manufacturing machinery – assessing machine error, uncertainty in-process and continuing development of new calibration methods. This includes machine tools, industrial robots & dimensional metrology systems such as coordinate measuring machines (CMMs). 

Error compensation in machine tools is a process of identifying and correcting errors (deviations from the ideal path) to improve accuracy and quality. It typically involves: 1) modelling the machine's geometric and thermal errors, 2) measuring these errors using tools like laser interferometers, and then 3) compensating for them by adjusting the tool path in the control system. Our research group has extensive experience in this area, investigating the use of emerging technologies like artificial intelligence for error prediction and real-time compensation to enhance overall machining quality and productivity. 

Still a relatively novel concept, there is significant industrial interest in integrating ML into manufacturing machinery for anomaly detection, proactive maintenance, and error avoidance and correction. This is achieved by developing robust & validated algorithms to allow machine tools to assess & adapt to their status/environment. From an efficiency point-of-view, we are also concentrated on developing interoperability within this area, so that ML algorithms are not limited to one specific machine, manufacturer, or type of sensor or controller. 

According to the National Physical Laboratory (NPL), traditional product verification processes typically account for 10-20% of the finished product cost. This research theme aims to minimise that cost by developing or adapting sensors & instruments for in-situ measurement and data processing. As part of our “Smart Workshop” project, we also have a network of sensors which constantly monitor temperature, air quality, vibration, and coolant concentration. From a research perspective, this data develops our fundamental understanding of machine tools and the parameters that affect quality, which in turn, allows us to help our industry partners improve their return-on-investment.  

Usually, the largest single cost in a manufacturing process is the procurement, commissioning, troubleshooting & validation of capital assets, such as machine tools. This research theme aims to de-risk and reduce those costs by improving agility and interoperability within manufacturing. We make use of advanced digital tools, including high-fidelity digital twins, to facilitate design and control at an early stage. Optioneering in the digital domain helps to provide confidence in a process before any large amounts of capital are expended. 

With similar advantages to the digital twinning of a machine or shop floor, tools from Virtual, Augmented and Mixed Reality can take this concept even further by creating an immersive experience in which 3D digital twin models can be arranged and interacted with in a virtual environment. The primary advantages of XR in manufacturing include faster product development, improved quality control through process simulation, and confidence in process safety via improved employee engagement during training. XR can also facilitate remote collaboration, optimise shop-floor workflow, and reduce operational risks by allowing virtual testing and hazard identification before physical implementation. We are developing models to take advantage of this technology at both the machine- and workshop-level.