TWI Annual Review - July 2008

Achievements in 2007

• Successful launch of 15 collaborative projects covering a wide range of technologies including intelligent electrical control systems, NDT of aircraft wiring, plastic electronics and medical implant development.
• Development of a strategy for TWI's Medical Sector.
• Organised three successful international events at TWI in the areas of nano, automotive and medical technology.
• Conducted a successful scoping study on the Economic and Social Research Council business engagement with the UK Health Sector.
• Developed a wind tunnel facility with infrared temperature measurement for characterising die attach and heat sink methods and materials.
• Successfully completed two large European collaborative projects on the performance and implementation of lead-free soldering.
• Assessed the thermal ageing performance of copper wire bonding in terms of intermetallic growth rates and joint resistance.

Future Plans

• Two electronics/medical panel meetings to be held in 2008.
• Development of a roadmap and strategic plan for electronics and sensors.
• Further develop TWI's approach and capabilities in the area of electronics thermal management product validation and reliability.
• Further develop TWI's activities in nanotechnology.
• Continue the development of novel TWI technologies such as Surfi-Sculpt^®, cold spray and micro-friction stir welding for electronics and medical applications.

Case Study TWI, in partnership with Vascutek Ltd and the Technology Strategy Board, is developing a new generation of endovascular devices for the treatment of abdominal aortic aneurysms (AAA) which would involve use of rapid automated manufacturing methods. AAA is a life-threatening disease which occurs when a section of the abdominal aorta, the body's main circulatory vessel, weakens and bulges outward to form a fragile, balloon-like swelling called an aneurysm. If the aneurysm ruptures, the patient is at high risk of death as a result of internal bleeding. Endovascular grafts such as the Anaconda manufactured by Vascutek Ltd are used to treat AAA. Currently, Vascutek use highly labour-intensive procedures for manufacturing the Anaconda (the endovascular device shown in the photograph). One of the most time-consuming operations is the attachment of the supporting Nitinol ring-stents to the polyester graft fabric. This is currently performed by hand sewing with needle and suture. New technologies such as ultrasonic welding, laser welding and adhesive bonding are being thoroughly investigated at TWI and the most effective technology will be taken to the next stage leading towards an automated manufacturing procedure. The new methods will be incorporated into a manufacturing unit and, following the specification of quality control techniques, the unit will be made ready for production.