Greensails
Project challenges
- Select appropriate manufacturing processes for prototype fabrication
- Assess designs to improve manufacturability, and identify suitable suppliers to facilitate build and assembly
- Generate a technology roadmap to support GT Wings in commercialisation of the product
Business challenge
Sustainability & Net Zero
Sector
Power & Energy
Technology or capability
Additive Manufacturing
The Challenge
GT Wings has developed a wind sail propulsion system, known as the AirWing, which can provide auxiliary power to a range of ship types from 20m vessels to large cargo carriers. GT Wings’ projections suggest that the retrofit of vessels with AirWing components can reduce carbon emissions and fuel costs by up to 30%, increasing to up to 50% for new vessels.
To further develop and test the AirWing concept, manufacture of a 20m tall prototype is planned. The design involves many complex parts and challenging geometries which may require novel techniques and approaches to manufacture.
The MTC were set the challenge of selecting appropriate manufacturing processes for prototype fabrication, assess designs to improve manufacturability, and identify suitable suppliers to facilitate build and assembly. Further to this, the MTC were also asked to provide support generating a technology roadmap to support GT Wings in commercialisation of the product.
MTC's Solution
- Design Review & Design for Manufacture and Assembly (DfMA): Through a “Design for X” approach, the MTC identified various opportunities to optimise the design of the AirWing, to optimise for manufacture and assembly of the product, while ensuring adherence to relevant industry standards and practices.
- Process Selection: The MTC assessed potential manufacturing processes for all components. The team utilised standard methods to select the optimal methods of manufacture, carried out handling and feeding analysis to optimise the assembly process, and suggested design improvements to facilitate right-first-time assembly. Using these conclusions enabled comprehensive assembly process flows to be generated for the AirWing product.
- Supplier Identification: The team identified and contacted a range of suitable UK-based manufacturers to obtain representative quotes for manufacture of all prototype components.
- Technology Roadmap: The MTC supported the customer in developing a technology roadmap for the product, providing a framework to inform and guide the business decision making process throughout the current project and into future commercialisation.
The MTC team came with a mindset to proactively help us through whatever challenge we faced at the time and adapted to the situation and need… We found the technology roadmap helpful - something we now use regularly!
George Thompson, Director, GT Wings
The Outcome
- The AirWing prototype design was optimised through application of DfX principles, enabling a “one-way” assembly process to maximise efficiency.
- Assembly sequencing was proposed for each component of the AirWing prototype.
- MTC utilised expertise in manufacturing techniques to identify appropriate methods-of-manufacture for the AirWing.
- MTC leveraged commercial awareness and business acumen to guide the generation of a technology roadmap for GT Wings.
Benefits to the Client
- A prototype AirWing design, optimised for manufacture and assembly, compliant with industry standards.
- Increased understanding in DfMA principles and in manufacturing processes, which can be applied to future AirWing design iterations.
- An assessment of the current UK supply chain and identification of potential suppliers (with associated ROM costs) who could support GT Wings in scale-up of manufacture.
- An understanding of the required steps towards commercialisation of AirWing and other products via technology roadmapping, to speed up time to market.
This project illustrated the benefits of bringing together a multi-skilled team of engineers, delivering a range of practical solutions to support GT Wings in developing their innovative product and their business.
Adam Brown, Technology Manager, The MTC
