糖心原创

Faculty of Engineering
 

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Lee Harper

Professor - Composites Manufacturing, Faculty of Engineering

Contact

  • workRoom B43 Advanced Manufacturing Building
    Jubilee Campus
    Wollaton Road
    Nottingham
    NG8 1BB
    UK
  • work0115 9513823

Biography

I am a Professor at the 糖心原创, where my research for the past 20 years has focussed on material and process developments for fibre reinforced polymer composites. I have particular interests in discontinuous fibre composites, which are suitable for producing sustainable, high volume components within the automotive sector. My research focusses on the development of automated manufacturing processes, which require an understanding of the underlying material science in order to offer technologies that are cost-competitive against traditional engineering materials. My work typically covers process development, process simulation and optimisation, which has significant industrial relevance.

The impact of my research has been far-reaching, reducing the mass and improving both the performance and economy of passenger vehicles. I co-developed the Directed Carbon Fibre Preforming (DCFP) process, in collaboration with Aston Martin Lagonda Ltd, which is a robotic chop and spray fibre delivery system for producing low cost, geometrically complex fibre preforms. I was responsible for developing a laboratory-scale manufacturing rig and a corresponding digital model to optimise the mesoscale material architecture, in order to minimise stochastic variability. This process made a significant contribution to the economic competitiveness of Aston Martin Lagonda, who employed the technique for the production of two structural components for the 12MY DBS, 12MY Virage, 13MY DB9 and Vanquish models. For the DBS model alone, 3,300 cars were sold in 42 countries at around 拢180,000 each, which equates to revenue of 拢594M. These two carbon fibre parts represented a weight saving of 52% and 44% compared to equivalent aluminium parts, with over 23 tonnes of material reaching the market. This work has received outstanding peer reviews, having featured as an impact case study in the 2014 REF exercise and has been disseminated in 16 journal publications to date (which have been collectively cited 514 times).

The thermoforming of complex composite parts has traditionally been difficult to automate, relies on labour intensive processes and generates large amounts of material waste (approximately 40% of fabric broad-goods). My most recent research has resulted in a simulation tool to optimise the manufacturing capability of continuous fibre preforms using an automated double diaphragm forming process. The simulation tool has been successfully used to perform virtual manufacturing studies to demonstrate that deep-draw parts can be produced with complex double curvature using low forming pressures. This has confirmed to a UK automotive OEM that automated forming can be achieved using low cost single-sided tooling for critical structural applications, underpinning the production of the next generation of McLaren carbon fibre supercar chassis in the UK. Project partner Hexcel Reinforcements Ltd (formerly Formax UK) has also developed new forming technologies from this research, reducing overall fabric waste to 5%. The successful outcomes from this project have helped to secure the future of Hexcel's R&T department in the East Midlands and added a significant new capability for Hexcel Corporation. This work has been disseminated in 11 journal papers to date, with the highest cited manuscript investigating the initiation and evolution of wrinkles during the fabric forming process.

My research track record and wide industrial network has led to many interesting consultancy projects with large OEMs and members of the composites supply chain, providing further opportunities for impact and knowledge exchange. Projects have ranged from producing composite demonstrator components for Airbus UK, Audi GmbH and Bentley Motors Ltd, to roadmaps and life-cycle assessments for Saudi Aramco and Nissan Motors respectively. One of the most noteworthy projects was working with the World Champion Freestyle Kayaker, James Reeves, to design and manufacture a high performance kayak using the DCFP process.

Expertise Summary

From 2017 to 2024 I was the Manager of the EPSRC Future Composites Manufacturing Research Hub, which was the largest single investment for fundamental research (TRL1-3) in composites manufacturing in the UK. I managed a funding portfolio of over 拢10m, working directly with 15 UK universities, 4 High Value Manufacturing Catapult centres and 43 industrial partners. The role required exceptional leadership and organisational skills and helped me to develop my personal network, raising my national profile as a leading researcher in composites engineering. Consequently, I am a member of the Composites Leadership Forum's Technology Working Group, responsible for delivery of the UK Composites strategy, reporting to the Department for Business, Energy and Industrial Strategy (BEIS). I am also an active member of the Society for the Advancement of Material and Process Engineering, chairing the Young Engineer and Student (YES) committee, which promotes collaboration, provides social engagement and shares expertise with the next generation of leaders within the composites sector. I am responsible for organising a series of annual events, including a student seminar and a design-and-make challenge to promote interest in composites to our young members.

There is a national skills shortage in the UK composites sector, so raising awareness of science and engineering of composite materials to the wider community is important to produce future talent. I have engaged in a number of outreach activities at secondary school level, including British Science Week and the Festival of Science and Curiosity in Nottingham, to inspire future generations to engage in STEM subjects. I also offer funded 10-week summer placements to final year undergraduates who are contemplating a postgraduate position, to attract suitable students for PhD and EngD positions in composites manufacturing. I teach the undergraduate Fibre Reinforced Composites Engineering module at the 糖心原创 and use my own research experiences to ensure the lecture content is current and industrially relevant, raising awareness of composite materials to younger members of the academic community. I have recently completed editing a text book for Elsevier on the 'Design and Manufacture of Structural Composites', which outlines the manufacturing challenges associated with fibre reinforced polymers for high-performance applications. The book includes contributions from leading experts in the field and provides an essential reference resource for members of industry, materials researchers, science and engineering students and educators who are working in the field of polymer matrix composites.

Teaching Summary

Module convenor for Fibre Reinforced Composites Engineering - MMME3054

Design tutor for Aerospace Design and Materials - MMME1049

Design tutor for Aerospace Design and Manufacture - MMME2033

Research Summary

Made Smarter Innovation - Materials Made Smarter Research Centre, EPSRC EP/V061798/1 (拢400k, PI) - 2021-2025

Selected Publications

  • CHEN, S., MCGREGOR, O. P. L., ENDRUWEIT, A., ELSMORE, M. T., DE FOCATIIS, D. S. A., HARPER, L. T. and WARRIOR, N. A., 2017. Composites Part A: Applied Science and Manufacturing. 95, 346-358
  • L T HARPER, D T BURN, M S JOHNSON and N A WARRIOR, 2017. Journal of Composite Materials.
  • HARPER, L. T., QIAN, C. C., LUCHOO, R. and WARRIOR, N. A., 2017. JOURNAL OF COMPOSITE MATERIALS. 51(17), 2389-2406
  • CORBRIDGE, D. M., HARPER, L. T., DE FOCATIIS, D. S. A. and WARRIOR, N. A., 2017. Composites Part A: Applied Science and Manufacturing. 95, 87-99

Past Research

  • Enhanced Characterization and Simulation Methods for Thermoplastic Overmoulding (ENACT), Innovate UK, Surface Generation, Michigan State University, (拢165k, PI) - 2020-2021
  • Design simulation tools and process improvements for NCF preforming, EPSRC Hub Core Project, University of Cambridge, University of Bath, Hexcel, Dassault System, GKN Aerospace, (拢243k, PI) - 2020-2023
  • Incorporation of thermoplastic in-situ polymerisation in double diaphragm forming, EPSRC Hub Feasibility 糖心原创, (拢50k, PI), 2020
  • High-Volume Composites Manufacturing Cell with Digital Twinning Capability, EPSRC Strategic Equipment Grant, (拢568k, PI) - 2019
  • CHASSIS, Innovate UK, Ford Motor Company, (拢165k, CI) - 2018-2020
  • Simulation of 3D curved composite sandwich panels, Hub Feasibility 糖心原创, EPSRC, (拢50k, CI) - 2018
  • Project Century, Innovate UK, GKN Land Systems (拢249k, CI) - 2016-2019
  • Thermoplastic Over-moulding for Structural Composite Automotive Applications (TOSCAA), IDP12 Innovate UK, Jaguar Land Rover (拢265k, PI) - 2016-2018
  • Affordable Composites for Lightweight Vehicles (ACLIV), IDP12 Innovate UK, Hexcel Reinforcements and Prodrive, (拢125K, PI) - 2015-2016
  • Affordable Lightweighting Through Pre-form Automation (ALPA) - Innovate UK, McLaren Automotive Ltd (拢241K, PI) - 2012-2014
  • Multi-architecture Composites by Compression Moulding, EPSRC CIMComp 拢650K, CI with Warrior, Mills (Cranfield) and Potluri (Manchester)) - 2011-2013
  • Advanced Manufacturing Supply Chain Initiative (AMSCI) - Cytec (拢290k, CI) - 2013
  • Forming multi-ply preforms, CIMComp Feasibility 糖心原创, EPSRC (拢50K, PI) - 2013
  • Hengshen Carbon Fibre, China, Industrial funding, (拢303K, CI) - 2013
  • Affordable Technologies for Lightweight Automotive Structures (ATLAS) - Transport iNET, Axxon Automotive, G D Cars - (拢200K, PI and project lead) - 2012-2013
  • Novel Platform for Niche Car Chassis, Niche Vehicle Network and Gardner Douglas Cars (拢83K, CI) - 2011
  • EPSRC Case Studentship with GE Aviation (拢88K, CI) - 2008-2011
  • EPSRC Case Studentship with Bentley Motors (拢88K, PI) - 2008-2011
  • Towards Affordable Recyclable Low Carbon Vehicle Structures (TARF) - EPSRC - Imperial College, University of Manchester, Brunel University, Coventry University, University of Exeter (拢450K, CI) - 2011-2014
  • iComposites Grand Challenge, TSB, GKN Aerospace (拢60K, CI) - 2010
  • Next generation composite structures from multi-architecture preform systems, Transport iNET, M Wright and Sons (拢279K, CI) - 2009-2010
  • Bentley Motors DCFP Manufacturing, industrial funding (拢310K, CI) - 2008-2011
  • Bentley Motors DCFP Modelling, industrial funding (拢504K, CI) - 2008-2011
  • EPSRC Platform Grant Fellowship in Composite Materials - 2007
  • YOUSEFI, N., EVANS, A.D., HARPER, L.T., MAPLES, H.A., JAMES, T. and BISMARCK, A., 2021. Composites Part A: Applied Science and Manufacturing. 142,
  • XIAO, ZHAOFEI, LIU, XIAOLING, HARPER, LEE T., ENDRUWEIT, ANDREAS and WARRIOR, NICHOLAS A., 2020. JOURNAL OF COMPOSITE MATERIALS. 54(20), 2739-2751
  • CHEN, S., MCGREGOR, O.P.L., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2020. International Journal of Material Forming. 13(6), 967-980
  • LIU, H., LIU, J., DING, Y., ZHENG, J., KONG, X., ZHOU, J., HARPER, L., BLACKMAN, B.R.K., KINLOCH, A.J. and DEAR, J.P., 2020. Journal of Materials Science. 55(33), 15741-15768
  • XIAO, Z., LIU, X., HARPER, L.T., ENDRUWEIT, A. and WARRIOR, N.A., 2020. Journal of Composite Materials. 54(20), 2739-2751
  • BUSSETTA, P., GOMES, R., CHEN, S., MCGREGOR, O.P.L., HARPER, L.T., HARRISON, P. and CORREIA, C., 2020. In: 18th European Conference on Composite Materials.
  • LIU, H., LIU, J., DING, Y., ZHOU, J., KONG, X., HARPER, L.T., BLACKMAN, B.R.K., FALZON, B.G. and DEAR, J.P., 2020. Composite Structures. 236,
  • YU, F., CHEN, S., VIISAINEN, J.V., SUTCLIFFE, M.P.F., HARPER, L.T. and WARRIOR, N.A., 2020. Composites Science and Technology. 191,
  • LIU, J., LIU, H., CHAI, H., HARPER, L.T., FALZON, B.G., BLACKMAN, B.R.K., KINLOCH, A.J. and DEAR, J.P., 2019. In:
  • CHEN, S., MCGREGOR, O.P.L., ENDRUWEIT, A., HARPER, L.T. and WARRIOR, N.A., 2019. In: 22nd International Conference on Composite Materials.
  • EVANS, A.D., HARPER, L.T., TURNER, T.A. and WARRIOR, N.A., 2019. In:
  • YU, F., CHEN, S., HARPER, L.T. and WARRIOR, N.A., 2019. In: 22nd International Conference on Composite Materials.
  • CONSTANTIN, H., HARPER, L. and KENNEDY, A. R., 2018. Journal of Materials Processing Technology. 255, 66-75
  • GAO, X., CHEN, M., YANG, X., HARPER, L., AHMED, I. and LU, J., 2018. Journal of the Mechanical Behavior of Biomedical Materials. 81, 72-82
  • CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2018. COMPOSITE STRUCTURES. 201, 570-581
  • ZHAO, Q., QIAN, C. C., HARPER, L. T. and WARRIOR, N. A., 2018. JOURNAL OF COMPOSITE MATERIALS. 52(16), 2163-2177
  • CORBRIDGE, D. M., HARPER, L. T., DE FOCATIIS, D. S. A. and WARRIOR, N. A., 2017. Composites Part A: Applied Science and Manufacturing. 95, 87-99
  • CHEN, S., MCGREGOR, O. P. L., ENDRUWEIT, A., ELSMORE, M. T., DE FOCATIIS, D. S. A., HARPER, L. T. and WARRIOR, N. A., 2017. Composites Part A: Applied Science and Manufacturing. 95, 346-358
  • L T HARPER, D T BURN, M S JOHNSON and N A WARRIOR, 2017. Journal of Composite Materials.
  • HARPER, L. T., QIAN, C. C., LUCHOO, R. and WARRIOR, N. A., 2017. JOURNAL OF COMPOSITE MATERIALS. 51(17), 2389-2406
  • XIAO, Z., HARPER, L. T., KENNEDY, A. R. and WARRIOR, N. A., 2017. COMPOSITE STRUCTURES. 182, 380-390
  • CHAKLADAR, N. D., HARPER, L. T. and PARSONS, A. J., 2016. J Mech Behav Biomed Mater. 57, 334-46
  • BURN, D. T., HARPER, L. T., JOHNSON, M., WARRIOR, N. A., NAGEL, U., YANG, L. and THOMASON, J., 2016. Journal of Materials Science. 51(16), 7699-7715
  • CHEN, S., MCGREGOR, O. P. L., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2016. Composites Part A: Applied Science and Manufacturing. 91, 156-167
  • A D EVANS, C C QIAN, T A TURNER, L T HARPER and N A WARRIOR, 2016. Composites Part A: Applied Science and Manufacturing. 90(November), 1-12
  • CHEN, S., HARPER, L. T., ENDRUWEIT, A. and WARRIOR, N. A., 2015. Composites Part A: Applied Science and Manufacturing. 76, 10-19
  • CHEN, S., ENDRUWEIT, A., HARPER, L. T. and WARRIOR, N. A., 2015. Composites Part A: Applied Science and Manufacturing. 71, 144-156
  • QIAN, C. C., HARPER, L. T., TURNER, T. A. and WARRIOR, N. A., 2015. Composites Part A: Applied Science and Manufacturing. 68, 417-424
  • QIAN, C. C., HARPER, L. T., TURNER, T. A. and WARRIOR, N. A., 2015. Composites Part A: Applied Science and Manufacturing. 68, 406-416
  • JOHANSON, K., HARPER, L. T., JOHNSON, M. S. and WARRIOR, N. A., 2015. COMPOSITES PART A-APPLIED SCIENCE AND MANUFACTURING. 68, 304-312
  • LIU X, HASAN MS, GRANT DM, HARPER LT, PARSONS AJ, PALMER G, RUDD CD and AHMED I, 2014. Journal of biomaterials applications. 29(5), 675-87
  • BUTLER-SMITH PW, AXINTE DA, DAINE M, KENNEDY AR, HARPER LT, BUCOURT JF, RAGUENEAU R, 2014. International Journal of Machine Tools and Manufacture.
  • HAN, N., AHMED, I., PARSONS, A.J., HARPER, L., SCOTCHFORD, C.A., SCAMMELL, B.E. and RUDD, C.D., 2013. Journal of Biomaterials Applications. 27(8), 990-1002
  • LIU, XIAOLING, GRANT, DAVID M., PARSONS, ANDREW J., HARPER, LEE T., RUDD, CHRIS D. and AHMED, IFTY, 2013. BioMed Research International. 2013, 10
  • QIAN, C., HARPER, L. T., TURNER, T. A. and WARRIOR, N. A., 2012. Computational Materials Science. 64, 106-111
  • HARPER, L.T., QIAN, C., TURNER, T.A., LI, S. and WARRIOR, N.A., 2012. Composites Science and Technology. 72(2), 204-210
  • HARPER, L.T., QIAN, C., TURNER, T.A., LI, S. and WARRIOR, N.A., 2012. Composites Science and Technology. 72(2), 225-234
  • HARPER, L. T., AHMED, I., FELFEL, R. M. and QIAN, C., 2012. Journal of the Mechanical Behavior of Biomedical Materials. 15(0), 13-23
  • FELFEL, R. M., AHMED, I., PARSONS, A. J., HARPER, L. T. and RUDD, C. D., 2012. Journal of Materials Science. 47(12), 4884-4894
  • TURNER, T. A., HARPER, L. T., WARRIOR, N. A. and CALISKAN, A., 2011. International Journal of Vehicle Structures & Systems. 3(2), 80-86
  • QIAN, C., HARPER, L.T., TURNER, T.A. and WARRIOR, N.A., 2011. Composites Part A: Applied Science and Manufacturing. 42(3), 293-302
  • LUCHOO, R., HARPER, L. T., WARRIOR, N. A. and DODWORTH, A., 2011. Three-dimensional numerical modelling of discontinuous fibre composite architectures: Plastics Rubber and Composites Plastics Rubber and Composites. 40(6-7), 356-362
  • LUCHOO, R., HARPER, L .T., BOND, M. D., DODWORTH, A. and WARRIOR, N. A, 2011. Macro-scale modelling of discontinuous fiber composites. In: 18th International Conference on Composite Materials
  • QIAN, C., HARPER, L .T., TURNER, T. A., LI, S. and WARRIOR, N. A, 2011. Determination of the size of representative volume elements for discontinuous fibre composites. In: 18th International Conference on Composite Materials
  • HARPER, L.T., TURNER, T.A., MARTIN, J.R.B. and WARRIOR, N.A., 2010. Journal of Composite Materials. 44(8), 931-951
  • LUCHOO, R., HARPER, L. T., BOND, M. D., WARRIOR, N. A. and DODWORTH, A., 2010. Net shape spray deposition for compression moulding of discontinuous fibre composites for high performance applications: Plastics Rubber and Composites Plastics Rubber and Composites. 39(3-5), 216-231
  • HARPER, L .T., LUCHOO, R., DODWORTH, A. and WARRIOR, N. A, 2010. Automated Charge Placement for Structural Moulding Compounds. In: SAMPE Seattle
  • LUCHOO, R., HARPER, L .T., BOND, M. D., DODWORTH, A. and WARRIOR, N. A, 2010. Numerical Macro Scale Modelling of Discontinuous Fibre Architectures. In: 14th European Conference on Composite Materials
  • ENDRUWEIT, A., HARPER, L.T., TURNER, T.A., WARRIOR, N.A. and LONG, A.C., 2010. Polymer Composites. 31(4), 569-580
  • HARPER, L. T., LUCHOO, R., BOND, M. D., WARRIOR, N. A. and DODWORTH, A., 2010. Automated Charge Placement for Structural Molding Compounds (SMC): Sampe Journal Sampe Journal. 46(5), 6-21
  • TURNER, T. A., HARPER, L .T. and WARRIOR, N. A, 2010. Automated manufacture of multi-fibre architecture for high performance composite structures. In: Opportunities for FRPs in the Motor Industry
  • HARPER, L. T., TURNER, T. A., MARTIN, J. R. B. and WARRIOR, N. A., 2009. Fiber Alignment in Directed Carbon Fiber Preforms - A Feasibility 糖心原创: Journal of Composite Materials Journal of Composite Materials. 43(1), 57-74
  • BOND, M. D., HARPER, L .T., TURNER, T. A. and WARRIOR, N. A, 2009. Full Field Strain Measurement of Notched Discontinuous Carbon Fibre Composites. In: 17th International Conference of Composite Materials
  • HARPER, L. T., DODWORTH, A., LUCHOO, R. and WARRIOR, N. A., 2009. . In: 17th International Conference of Composite Materials
  • ENDRUWEIT, A., HARPER, L.T., TURNER, T.A., WARRIOR, N.A. and LONG, A.C., 2008. Composites Part A: Applied Science and Manufacturing. 39(10), 1660-1669
  • TURNER, T. A., HARPER, L. T., WARRIOR, N. A. and RUDD, C. D., 2008. Low-cost carbon-fibre-based automotive body panel systems: a performance and manufacturing cost comparison: Proceedings of the Institution of Mechanical Engineers Part D-Journal of Automobile Engineering Proceedings of the Institution of Mechanical Engineers Part D-Journal of Automobile Engineering. 222(D1), 53-63
  • ENDRUWEIT, A., HARPER, L .T., TURNER, T. A., WARRIOR, N. A. and LONG, A. C., 2008. The Permeability of Random Discontinuous Carbon Fibre Preforms. In: 13th European Conference on Composite Materials
  • HARPER, L .T., TURNER, T. A., MARTIN, J. R. B. and WARRIOR, N. A, 2008. Integrated Directed Carbon Fibre Preforming. In: 29th SAMPE EUROPE International Conference
  • HARPER, L. T., TURNER, T. A., WARRIOR, N. A. and RUDD, C. D., 2007. Characterisation of random carbon fibre composites from a directed fibre preforming process: The effect of tow filamentisation: Composites Part a-Applied Science and Manufacturing Composites Part a-Applied Science and Manufacturing. 38(3), 755-770
  • HARPER, L. T., TURNER, T. A. and WARRIOR, N. A., 2007. . In: 16th International Conference on Composite Materials
  • HARPER, L. T., TURNER, T. A., WARRIOR, N. A. and RUDD, C. D., 2006. Characterisation of random carbon fibre composites from a directed fibre preforming process: The effect of fibre length: Composites Part a-Applied Science and Manufacturing Composites Part a-Applied Science and Manufacturing. 37(11), 1863-1878
  • HARPER, L. T., TURNER, T. A., WARRIOR, N. A., DAHL, J. S. and RUDD, C. D., 2006. Characterisation of random carbon fibre composites from a directed fibre preforming process: Analysis of microstructural parameters: Composites Part a-Applied Science and Manufacturing Composites Part a-Applied Science and Manufacturing. 37(11), 2136-2147
  • HARPER, L. T, TURNER, T. A. and WARRIOR, N. A., 2006. A computational method for investigating the stochastic nature of discontinuous meso structures. In: Texcomp 8
  • HARPER, L. T, TURNER, T.A, WARRIOR, N. A and RUDD, C. D, 2006. Low Cost Carbon-Fiber based Automotive Body Panel Systems. In: SAMPE Europe Conference
  • HARPER, L. T., TURNER, T. A., WARRIOR, N. A. and RUDD, C. D., 2005. Automated preform manufacture for affordable lightweight body structures. In: SAMPE Europe Conference
  • HARPER, L. T, TURNER, T.A, WARRIOR, N. A and RUDD, C. D, 2005. Coverage and mechanical properties of spray-processed random carbon fibre composites. In: ICCM 15
  • TURNER, T. A., WARRIOR, N. A., RUDD, C. D. and HARPER, L. T., 2005. Spray-processed carbon composites for affordable lightweight body structures. In: Lean Weight Vehicles 6
  • SCHUBEL, P. J., HARPER, L. T, TURNER, T.A, WARRIOR, N. A, RUDD, C. D and KENDALL, K. N., 2004. Surface analysis of "Class A" polymer composite substrates for the automotive industry. In: 4th Asian-Australasian Conference on Composite Materials Woodhead Publishing.
  • WARRIOR, N. A., RUDD, C. D., TURNER, T. A., SCHUBEL, P. J. and HARPER, L. T., 2004. Affordable Lightweight Body Structures. In: IOM3 Materials Congress
  • WARRIOR, N. A, HARPER, L. T, TURNER, T. A., SCHUBEL, P. J., RUDD, C. D. and KENDALL, K. N., 2004. Affordable Lightweight Body Structures (ALBOS). In: JSAE Annual Congress
  • WARRIOR, N. A., RUDD, C. D., HARPER, L. T., TURNER, T. A. and SCHUBEL, P. J., 2003. Affordable Lightweight BOdy Structures. In: 5th International Conference on Materials for Lean Weight Vehicles

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