Gripple Case study report - collaborating with business

Pictured: Aidan Mullen, R&D Manager, Tom Fox, Technical Team Leader and Jack Hartley, Technical Engineer (Gripple); with CDT project team members Jozef McGowan, Lucas Cook, Jack Krohn, Dillon Frith and  Tom Cole (not pictured: Kate Bowers).

The global brand Gripple is a leading R&D and manufacturing company based in Sheffield that specialises in metallic wire joining and tensioning, and related products. Gripple’s products are used in a very wide range of applications and industries, such as load bearing suspension systems, agricultural fencing, transportation catenary systems and construction, which means Gripple products must be optimised for a very wide range of materials and conditions.

As part of their PG Diploma in Professional Skills programme, a group of six PhD researchers in the EPSRC Advanced Metallics Centre for Doctoral Training at The University of Sheffield undertook a short collaborative research project with Gripple. The project aimed to identify opportunities for optimisation of one of the company’s products when exposed to challenging environments during regular service, while retaining the functionality of the product.

Following initial market research into Gripple’s key product areas and the wider sector, the students were invited to one of their manufacturing sites to gain a better understanding of their processes and begin to engage with the team at the business, with whom they would share regular updates and interactions throughout the project timeline.

Using British Standards specifications as a baseline allowed the group to determine their experimental parameters for assessing product performance under demanding conditions. These specifications were applied alongside other common performance factors such as installation compatibility, tensile strength, flexibility, material compatibility with the full complement of Gripple products, and manufacturing processes. 

The team first identified and considered several approaches for innovation in the materials used, including the use of coatings, composite layups (where layers of different materials are used to benefit from a mix of material properties), ceramic materials, and new metallic materials. Through the research process, many of these approaches were rejected as they did not meet material compatibility, installation practices or ductility requirements. As a next step, they set about identifying a novel material that would offer enhanced properties and allow for compatibility with current installation and manufacturing processes. 

To do so, they applied microstructural tests of each material, and compared them with ‘industrial standard’ stainless steel and galvanised carbon steel. Finally, the team assessed each contender’s performance under extreme loads, manufacturability with the correct surface roughness and susceptibility of performance to detrimental chemical and electrochemical reactions. 

As a result of these investigations, the team produced a professional report for Gripple to set out their findings and recommendations, and gave a presentation at the Gripple site as a demonstration of their business-level skills.

Aidan Mullen, R&D Manager for Gripple said:

From the outset, the team approached the project in a professional and organised manner, establishing regular catch-ups, arranging site visits and planning a structured programme of experimental work. Communication throughout the project was excellent; seeking additional detail to ensure their work aligned with our requirements. They were receptive to feedback and willing to adapt their focus to consider not only the technical aspects of potential solutions, but also the practical business considerations such as cost, availability and feasibility. Overall, the group demonstrated a positive attitude, strong collaboration, effective communication and a genuine commitment to delivering valuable outcomes for Gripple.

Aidan Mullen

R&D Manager, Gripple