Manufacturing Success - 14 March 2012 High value manufacturing, an SME Case Study Ian Warrington, Project Manager MG Sanders Ltd

An overview of our capability Contract Case Study-Future Energy “SME`s make up a half of all jobs in the UK and account for half of our GDP” (B2B Int.) An overview of our capability Contract Case Study-Future Energy

Situated in Stone, 30 miles north of Birmingham in Central England. Established 38 years Under new ownership since January 2006: Rubicon Partners Industries LLP. 55 employees, T/O £8.5m (2011) 7000m2 Engineering & Metallurgical facility

Activity Tungsten alloy blending, pressing & vacuum sintering 6 April 2017 Activity Tungsten alloy blending, pressing & vacuum sintering Multi–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys Pre-production – Prototype Manufacture Clean room assembly High Volume Pharmaceutical Valve Stem production Design & Manufacture of UHV & VHF Military Antennas ‘End of life’ process re-definition and manufacture Reverse Engineering & Sub-Contract manufacture ◄ Tungsten LB-SRP

Quality Approvals ISO 9001 AS 9100 Rev B

6 April 2017 Some of our customers: ◄ Tungsten LB-SRP

Activity Tungsten alloy blending, pressing & vacuum sintering 6 April 2017 Activity Tungsten alloy blending, pressing & vacuum sintering ◄ Tungsten LB-SRP Raw Material: Fully integrated Powder Metallurgy manufacture, pressing, sintering and Heat Treatment with “Total manufacturing traceability”

6 April 2017 Activity Multi–axis CNC Milling, Turning, Grinding, EDM: Tungsten (W), Refractory and exotic Ni, Fe, Al based alloys ◄ Tungsten LB-SRP

Activity High Volume Pharmaceutical Valve Stem production 6 April 2017 High Volume Pharmaceutical Valve Stem production Circa 1.2m/month Activity ◄ Tungsten LB-SRP

Activity Design & Manufacture of Military Broadband Antennas 6 April 2017 Activity Design & Manufacture of Military Broadband Antennas HF, VHF and UHF Bowman Manpack and Vehicle Elevated or Ground based units ◄ Tungsten LB-SRP

AEROSPACE Control surfaces Flutter weights Boeing 737/767/777 ATR 76 Airbus Military

AEROSPACE Rotor Balance AW101 AW139 AW149 Lynx Wildcat

F1 Aerodynamic Ballast

Nuclear Engineering- Radiation Shielding Oil Well Logging Instrumentation Nuclear Waste Encapsulation Shielding - Sellafield

LHC Tungsten Cylinder Inserts (for Target Attenuator experimental Areas) CLIC RF Accelerating Structures –UKTI- OMIS/STFC support Ultra precise machining, diffusion bonding

Business Development-Access New Markets Identify innovative & technically demanding opportunities, in Tungsten and other exotic materials or processes, that can be commercially exploited to generate incremental high value revenue.        Focus on materials competence, skills and future markets

Business Development – Future Energy The world's largest Fusion tokamak, JET (Joint European Torus), has produced 16 megawatts of fusion power and proved the technical feasibility of fusion using deuterium and tritium, currently considered the most efficient fuels. The challenge now is to prove fusion can work on a power plant scale. 1st wall upgrade to the Joint European Torus (JET) – €48m budget – EFDA funded (EU Commission) to evaluate materials for ITER construction Identify tender opportunities -expression of interest

Evaluate Plasma surface interaction for ITER materials: Beryllium 6 April 2017 Evaluate Plasma surface interaction for ITER materials: Beryllium W-coated CFC Inconel + Be Bulk W-LBSRP Previously CFC W Divertor Module - power handling surface. Bulk W-load bearing septum replacement plates for the divertor Form part of the Divertor module to evaluate Tungsten for power handling surfaces.

6 April 2017 Competencies & skills Validation of CATIA V/STEP models and provision of full manufacturing drawings Fusion related materials understanding Development of manufacturing processes and techniques Production of tooling and jig fixtures Complex 5 axis machining Accurate, clean assembly of complex geometry items for UHV and demanding environments (JET QUA 500) Comprehensive inspection to CAD models including CMM, Surface Measurement & SPC.

Contract Award Time from expression of interest to tender response deadline = 3 months. Complex tender to interpret: CATIA V model, prototype design & materials/technical specification. Open comments & questions circulated to invited tendering companies. As a potential new supplier an audit visit followed tender submission to assess capability. Contract preparation forms, followed by agreement in principle (without prejudice), fixed price & rigid contractual terms (EU Commission), bank guarantee.

Contract Award Formal contract award (12 months + from Expression of Interest) Value: €5.3m Prototypes (including orders outside of contract) to test and allow final design freeze for manufacture. Deliverables & Milestones mutually acceptable & achievable, including payments.

6 April 2017 Tungsten - LBSRP Tungsten LBSRP MGS Tungsten for plasma facing components - independently tested & qualified;

50μm reference tolerances 6 April 2017 50 assemblies / 80Kg each 5 exotic materials 1,600 parts /assembly 80,000 parts total Clean room assembly 50μm reference tolerances

6 April 2017

Installation of a solid tungsten divertor module between neighbours with dedicated spinal Remote Handling tool Courtesy M. Woollard

Wall & Divertor completed mid 2011

Business Development The next steps : International fusion research is following a roadmap to achieve power generation within 30 years. It focuses on three main projects: ITER – a multinational project (47%) EU, with a €10bn budget that is being built in the south of France. ITER will be a 500 megawatt tokamak (equivalent to a small power plant) and aims to confirm that fusion power will be possible on a commercial scale; IFMIF (International Fusion Materials Irradiation Facility) – a device that will test the materials needed in a fusion power station, planned to operate in parallel with ITER;

ITER Divertor targets

Business Development DEMO – a demonstration power plant supplying fusion electricity to the grid. This is being designed now and would be constructed during ITER and IFMIF operation. If successful, it will be followed by the first generation of commercial fusion power stations. We are looking for partners to collaborate in these high value manufacturing opportunities. Thank you for your attention!