The Project · DIGI-HSMC, Innovate UK Project No. 10183007

THE PROJECT

Developing digital high-shear melt conditioning for resource-efficient aluminium processing

DIGI-HSMC is a UK research and development project developing an integrated approach to aluminium melt processing by combining High-Shear Melt Conditioning, real-time sensing and a physics-informed digital twin.

UKRI Innovate UK Funded by Innovate UKInnovate UK Project No. 10183007
PROJECT PERIOD July 2026 – March 2027

DIGI-HSMC at a glance

PROJECT
Digital High-Shear Melt Conditioning for Resource-Efficient Aluminium Processing
PROJECT NUMBER
10183007
PROJECT TYPE
UK research and development project
PROJECT PERIOD
July 2026 – March 2027
TECHNICAL FOCUS
High-Shear Melt ConditioningReal-time sensingPhysics-informed digital twin

01 · RATIONALE

Why is DIGI-HSMC being developed?

Aluminium melt processing can be affected by variability in melt quality, process conditions and feedstock. Limited visibility into the condition of the melt can make process decisions dependent on operator experience and judgement.

DIGI-HSMC is developing an integrated approach intended to make the melt-conditioning process more measurable by connecting physical melt treatment with process sensing and digital interpretation.

The industrial challenge →
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02 · DEVELOPMENT SCOPE

What the project is developing

Four connected development components, integrated as one system.

Explore the Technology →
  1. 01

    HIGH-SHEAR MELT CONDITIONING

    The physical melt-conditioning process based around a rotor–stator system.

  2. 02

    CERAMIC ROTOR–STATOR

    An enhanced rotor–stator component being developed using silicon nitride ceramic.

  3. 03

    REAL-TIME SENSING & MONITORING

    Process information including temperature, torque and acoustic data is captured and brought together.

  4. 04

    PHYSICS-INFORMED DIGITAL TWIN

    A digital model is being developed to interpret process information and represent aspects of melt behaviour.

These are development components of the project, not a finished commercial product.

03 · DEVELOPMENT PATHWAY

From research to integrated system

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Stages are shown in sequence without dates.

04 · CONSORTIUM

Four organisations. Complementary expertise.

DIGI-HSMC brings together four organisations with complementary capabilities across high-shear melt conditioning, research and modelling, ceramic engineering and industrial application.

  • Zyomax Limited 01PROJECT LEAD

    Zyomax Limited

    Project lead and HSMC technology / system integration expertise.

  • BCAST, Brunel University of London 02

    BCAST · Brunel University of London

    Research and materials / process expertise.

  • International Syalons 03

    International Syalons

    Advanced ceramic engineering and silicon nitride expertise.

  • Aeromet International Limited 04

    Aeromet International Limited

    Industrial application and validation expertise.

Meet the consortium →

05 · OBJECTIVES

What the project aims to achieve

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06 · STRUCTURE

How the project is structured

DIGI-HSMC is delivered through defined work packages covering project management, requirements and design, technical development, integration, and testing and validation, with exploitation and commercial readiness where set out in the approved project plan.

FIG. P-01 · WORK-PACKAGE STRUCTUREOFFICIAL WP MAPPING
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The project is structured across seven work packages, delivered by the four consortium partners.

07 · VALIDATION

From development to validation

The project is designed to move from individual technical components towards an integrated system that can be tested and evaluated under relevant industrial conditions.

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Validation has not yet been completed. No validation results are published.

Prior HSMC evidence ≠ DIGI-HSMC result

08 · TIMELINE

The project pathway

PROJECT STARTJuly 2026
PROJECT ENDMarch 2027
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Stages are not dated.

09 · STATUS

A project in development

DIGI-HSMC is being developed through a structured research, engineering, integration and validation programme.

Evidence-led development

The project website distinguishes between different levels of evidence. Every claim carries one of these markers.

INDUSTRY CONTEXT
External or documented industry information
PRIOR RESULT
Evidence generated before or outside the current DIGI-HSMC project
PROJECT OBJECTIVE
An aim the project has set out to address
PROJECT TARGET
A defined outcome the project is working towards
EXPECTED IMPACT
Potential contribution associated with successful development
VERIFIED DIGI-HSMC RESULT
Project evidence formally reviewed and approved for publication. None published yet.

10 · EXPECTED IMPACT

What the project is working towards

The project is intended to contribute to more resource-efficient aluminium processing through improved process visibility, melt conditioning and control.

  • EXPECTED IMPACTENERGY & EMISSIONS
  • EXPECTED IMPACTRESOURCE EFFICIENCY
  • EXPECTED IMPACTRECYCLING & CIRCULARITY
Explore the expected impact →

11 · COMMERCIALISATION PATHWAY

From R&D to future industrial application

DIGI-HSMC is developing the technology and evidence base needed to support future industrial application and commercialisation.

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The technology is under development and is not commercially available.

Explore the DIGI-HSMC project

Follow the project's objectives, technical development, consortium structure, validation pathway and expected impact.