Rapdasa 2015 Abstract Booklet PDF

Additive Manufacturing
Transforming
ideas into business
th
16 INTERNATIONAL CONFERENCE
4 - 6 November 2015, Roodevallei, Pretoria, South Africa
Sponsors
Platinum
science
& technology
Department:
Science and Technology
Gold
Silver
Bronze
Contents
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3
4
5
6
18
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22
24
26
Foreword
Technical Committee
Organising Committee
Exhibitors
Keynote Speakers
Programme Overview
Programme Pre-Conference Seminar
Programme Day 1
Programme Day 2
Programme Day 3
Abstracts
- Day 1 - Bateleur
- Day 2 - Bateleur
- Day 2 - Fish Eagle
- Day 2 - Cormorant
- Day 2 - Barn Owl
- Day 3 - Bateleur
- Day 3 - Cormorant
- Day 3 - Barn Owl
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58
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RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business
Foreword
Following the success of the previous RAPDASA conference, held in Stellenbosch in
November 2014, Aerosud ITC and the CSIR are honoured to host and present the
16th Annual International RAPDASA conference.
Additive Manufacturing (AM), better known as 3D Printing, has matured from a
prototyping technology into a fully-fledged manufacturing technology. In the 2014
Wohlers report, Dr. Terry Wohlers reported that 35% of all AM applications in 2014
were for final part production. We anticipate that this number will further grow in
2015. AM products are increasingly being used as final products in the aerospace,
automotive, medical, consumer product and other industries. Internationally and locally, unprecedented innovation has been seen in the field of AM.
In South Africa, the growth of the AM industry is evident and widespread application
of the technology can be seen in the country. This has been reflected in the RAPDASA
conference where year on year growth can be seen. This year is no exception with
more than 200 attendees from industry, academia, research and government.
Our conference theme for this year is Additive Manufacturing: Transforming Ideas
into Business. In keeping with this theme, we as organising committee put in a special effort to encourage industry to participate in the conference. This is evident from
the conference program, where we will have more than 40% of the conference presentations from the private sector, both local and international. This is a significant
achievement for the conference organising team.
Our conference program is designed to offer participants the opportunity to:

Gain exposure to the latest developments in the field of AM;

Share knowledge and ideas through presentations and technical
discussions;
Network with experts from industry, R&D institutions, academia and
government;
Gain firsthand knowledge of the latest AM technology through the
conference exhibition.
We hope that you enjoy the conference, and encourage you to participate and
broaden your collaboration network.
General Information - Technical Committee

Prof. Willie Du Preez
Prof. Sanat Agrawal
Central University of
Japee University of
Engineering & Technology Technology
Mrs. Maritha Theron

CSIR
(Convenor)
Mr. John Barnes

RTI International Metals
Dr. Richard Grylls

SLM Solutions
Prof. Michle Truscott

Technology
Dr. Thorsten Becker

Stellenbosch University
Prof. Jorrie Jordaan

Technology
Dr. Dawie van den

Heever
Mr. Jeff Benson

CSIR
Dr. Kobus Van der Walt

Dr. Yashwant Modi
Japee University of
Engineering & Technology Technology
Prof. Uwe Berger

Aalen University of
Applied Sciences
Mr. Herman Rossouw

CSIR
Prof. Milan Brandt

RMIT University
Dr. Igor Yadroitsau

Dr. Joseph Santner
Northern Illinois University Central University of
Technology
Prof. Kristiaan Schreve
Mr. Herman Burger

CSIR
Dr. George Vicatos

University of Cape Town
Prof. Federico
Dr. Ian Campbell
Loughborough University Sciammarella
Northern Illinois University
Prof. Oliver Damm
Mr. Charl Smal

CSIR
Prof. Olaf Diegel

Lund University
Prof. Dimitri Dimitrov
General Information - Organising Committee

The 16th Annual International RAPDASA Conference is organised
by Aerosud ITC and the CSIR.
Organising Committee
Marius Vermeulen (Conference Chair)
Hardus Greyling (Co-Chair)
Maritha Theron (Technical Committee)
Yvonne Raman (Finances)
Phumi Hlope (Secretariat)
Conference Secretariat and Registration
Phumi Hlope
Tel: +27 (0)12 662 5322
Fax.: +27 (0)86 262 2741
E-mail: conference@rapdasa.org
Conference Technical Committee
Maritha Theron
Tel: +27 (0)12 841 4449
E-mail: abstracts@rapdasa.org
Conference Invoicing and Finances
Yvonne Raman
Tel: +27 (0)12 662 5027
E-mail: finance@rapdasa.org
General Queries
Marius Vermeulen / Hardus Greyling
general@rapdasa.org
Exhibitors
Keynote Speaker
Sarah Wild
Science journalist
Wild on Science, South Africa
sarah@mg.co.za
Biography
Sarah Wild is a multi-award-winning science journalist. She studied physics, electronics and English literature at Rhodes University in an effort to make herself unemployable. It didnt work and she now writes about particle physics, cosmology and
everything in between. She has worked as science editor at Business Day and the
Mail & Guardian. In 2012, she published her first full-length non-fiction book Searching African Skies: The Square Kilometre Array and South Africas Quest to Hear the Songs
of the Stars, and in 2013 she was named the best science journalist in Africa by
Siemens in their 2013 Pan-African Profiles Awards. In 2015, she published her second book Innovation: Shaping South Africa through Science, and was a finalist in the
CNN-Multichoice African Journalist Awards. Wild contributes to the Mail & Guardian,
AfricaCheck, the Financial Mail and Independent Newspaper titles, among others.
SHAPING SOUTH AFRICA THROUGH SCIENCE
ABSTRACT
Should scientists talk to the public about their research? What role does the media
play in fostering science communication in the public discourse? Wild, who has written about South African science for a number of popular publications, will talk about
science in society, the role of the media in science communication and how science
should shape South Africa and decision making.
Keynote Speaker
Graham Blackbeard
Managing Director
Southern Implants, Pretoria, South Africa
graham@southernimplants.com
Biography
Graham Blackbeard has an MSc in Engineering. In 1983 and 1984 he was a Rotary
Foundation Scholar at the Division of Artificial Organs at the University of Utah. He
has developed and manufactured heart valves, artificial hearts, various dental implant products, a tempro-mandibular joint prosthesis and various orthopaedic devices over the past 25 years. He has a special interest in stress analysis and fatigue of
dental implant componentry. He has presented at a number of dental meetings and
co-authored several international publications. Material science, surface engineering and the bone implant interface are his main areas of research. He is the current
Managing Director of Southern Implants (Pty) Ltd.
MEDICAL DEVICE APPLICATIONS
ABSTRACT
This presentation will review the applications of Rapid Prototyping that have been
used by Southern Implants, together with the difficulties and successes. Hindrances
to greater application of Rapid Prototyping in Medical Devices, will be discussed.
Keynote Speaker
Paul Potgieter (Jnr)
Program Manager and Director Aerosud Innovation

AHRLAC Holdings, Pretoria, South Africa
pauljnr@aerosud.co.za
Biography
Mr. Potgieter is a glider, microlight and private pilot license holder. He completed a
B-Ing at the University of Pretoria (specialised in aeronautical engineering). In 2004
he joined Aerosud as engineer, working on the development of a new jet engine. He
started the Aerosud Innovation and Training Centre in 2006 with various development programs.
In 2008 the AHRLAC program was launched to develop the aircraft and team to
first flight and beyond. He flies the chase planes for the AHRLAC test program and
also occasionally serves as Flight Test Engineer in AHRLAC during flight testing. Mr.
Potgieter received the Top 35 under 35 Award Young People in International Affairs
and serves on the Aerospace Leadership Academy with Elon Musk and Mark Shuttleworth. The AHRLAC program was nominated for the 2015 International Aerospace
Innovation Award of the Year in Washington DC.
AHRLAC DESIGN, BUILD, FLY
ABSTRACT
The informal journey of developing a Multi Role aircraft in South Africa. What it takes
to get a project going, growing, designed and manufactured, flying AHRLAC and
putting the aircraft in production.
Keynote Speaker
Michaella Janse van Vuuren
Nomili, Pretoria, South Africa
michaella@nomili.co.za
Biography
Michaella Janse van Vuuren is an artist and designer who has a PhD in Electrical
Engineering. She has been involved in 3D printing since 2006 when she did her
post doctorate in Custom Medical Implant design at the CUT. In 2008 she founded
Nomili, an innovative multidisciplinary research, consulting and 3D printed product
development studio. Her Chrysanthemum centrepiece was voted the Most Beautiful
Object in South Africa at Design Indaba 2009. In 2012 she was the VISI emerging
designer of the year and in 2014 she was named one of the City Press 100 world class
South Africans. Her ground-breaking 3D Printed Garden of Eden fashion collection
debuted in the 3D Printshow catwalk in New York in 2014. The Horse Marionette, a
fine art piece, was on exhibition for two years in the London Science museum, and
is now part of the Museums permanent collection. Michaella founded the Agents
of the 3D revolution in 2013; through exhibitions and seminars the public is given
access and education in cutting edge technology.
3D PRINTING AND MULTIDISCIPLINARY INNOVATION
ABSTRACT
Digital manufacturing is enabling people from many diverse backgrounds to share
their expertise and work together to create innovative products. Michaella Janse van
Vuuren has excelled in multiple disciplines from her PhD in Electrical Engineering
and post doctorate in medical implant design to being an internationally renowned
3D print designer, artist and an innovator in education. In this talk she discusses the
joys, difficulties and lessons learnt from working across multidisciplinary boundaries.
These lessons will hopefully help the audience to better navigate these rewarding
but often inhospitable landscapes.
Keynote Speaker
Marius Vermeulen
Project Manager: Additive Manufacturing

Aerosud ITC, Pretoria, South Africa
m.vermeulen@aerosud.co.za
Biography
Marius Vermeulen is a Senior Engineer at the Aerosud Innovation Centre, a South
African based company in the Aviation sector, and is the Program Manager on Additive Manufacturing. He completed his Bachelors degree in Computer Engineering at
the University of Pretoria in 2004. He started his career in the aerospace industry and
has been at Aerosud for the last ten years focusing on the development of various
manufacturing processes for the aviation industry.
He was introduced to Additive Manufacturing in 2006, and became actively involved
in research regarding the use of the technology for the aviation industry. He is part
of the management committee of RAPDASA as well as the executive committee
for ASTM F42, focused on the development of international standards for Additive
Manufacturing.
Marius is leading project AeroSwift which entails the development of a new large
scale, powder bed metal Additive Manufacturing system in South Africa
AEROSWIFT A SOUTH AFRICAN DEVELOPED METAL ADDITIVE
MANUFACTURING MACHINE
ABSTRACT
Additive Manufacturing (AM) or 3D printing is generally acknowledged as a new,
disruptive manufacturing technology that will have a significant impact on the
manufacturing industry in the future. AM of components in advanced metals, specifically titanium, is highly relevant to the so called high value, low volume industries
such as aerospace and medical. As a result, the commercial use of AM technologies is
constantly on the rise in these markets.
With this in mind, and taking into consideration the South African drive towards
local titanium beneficiation, a South African project was launched between Aerosud
Innovation Centre and the CSIR. The project led to the development of the worlds
largest and fastest metal powder bed 3D printer.
The talk will introduce the audience to the project and give an overview of the development of the Aeroswift machine
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Keynote Speaker
Terry Wohlers
President, Wohlers Associates, Inc

Fort Collins, Colorado, USA
tw@wohlersassociates.com
Biography
Terry Wohlers is the founder, principal consultant, and president of Wohlers
Associates Inc., an independent consulting firm that was launched 28 years ago. He
and his team have provided consulting assistance to more than 240 organizations in
24 countries, as well as to 150+ companies in the investment community. Wohlers
has authored 400 books, articles, and technical papers and has given more than 125
keynote presentations on five continents. He has twice served as a featured speaker
at events held at the White House in the U.S. Wohlers has appeared on many television and radio news programs and is cited frequently in the media and press. He is
a principal author of the Wohlers Report, the undisputed industry-leading report on
the subject of additive manufacturing for two decades. In 2004, Wohlers received an
Honorary Doctoral Degree from Central University of Technology in Bloemfontein,
South Africa.
THE FUTURE OF ADDITIVE MANUFACTURING
ABSTRACT
Corporations, government agencies, researchers, and others worldwide have shown
interest in additive manufacturing technology and 3D printing-terms that are used
interchangeably-in ways that have not been seen in the past. Organizations are trying to understand where it is headed and how they fit in. Many are awestruck by
the technology and investing large amounts of money. Wohlers will underscore key
developments that have led to this phenomenon and will emphasize some of the
most important growth trends from the recent past, and prospects for the future.
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Keynote Speaker
Peter Sander
Vice President & Manager Emerging Technologies &

Concepts Airbus, Hamburg, Germany
peter.sander@airbus.com
Biography
Peter Sander has 34 years experience in the aviation industry, with a wide range of
different responsibilities. Starting from manufacturing tasks like Industrial Engineering he managed tool design and production-, manufacturing engineering teams,
managed sheet metal production and CRFP production centers and the German
A380 structure assembly and equipping for years. In 2010 he started to build up
within R&T a new innovation cell in Germany with one focus on ALM. Today Sander
is one of the European ALM Project leaders and also part of the Airbus Group ALM
Roadmap team.
ON THE WAY TO ADDITIVE LAYER MANUFACTURING: CHANCES & CHALLENGES
FOR THE FUTURE INDUSTRIAL PRODUCTION
ABSTRACT
This presentation provides an overview of ALM for industrial production, beginning
with the key success factors as well as information on enabling material & process
details. Details will be provided how to develop and incorporate this new manufacturing technology in a new industrial value chain, with specific emphasizes on the
design, stress and management functions of industrial production. The presentation
will conclude with a number of examples of flying- and demonstrator projects out of
a scope of more than120 ongoing or finalized ALM projects. Emphasize will also be
placed on future industrial needs
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Keynote Speaker
Henner Schneborn
Member of the Board of Directors

(Corporate Development and Innovations) and
Shareholder of the SLM Solutions Group AG
Henner.Schoeneborn@slm-solutions.com
Biography
Mr. Schneborn holds an engineering degree in design and construction as well as
a degree in business administration. He started his career as an Applications- and
Consultant Engineer for Laser, Robotics and Milling Centers. In 1993 he was appointed Product Manager for Rapid Prototyping-Technologies with MCP-HEK Tooling
Technologies. As Director / Board Member he was responsible for the introduction
of the SLM Technology in the company. In 2008 he became Shareholder and Head
of the SLM Technology Group within MTT Technologies Germany, and participated
in the establishment of SLM Solutions GmbH in 2011. After serving as Chief Operations Officer and Chief Technical Officer of SLM Solutions GmbH and SLM Solutions
NA, Inc he is today Member of the Board of Directors (Corporate Development and
Innovations) and Shareholder of the SLM Solutions Group AG.
POWDER BED FUSION AND OTHER AM POWDER SYSTEMS; FUTURE DEVELOPMENTS, REQUIREMENTS AND NEEDS FOR THE NEXT GENERATION OF MACHINES AND PRACTICALLY PROCESS MONITORING OR CONTROL
ABSTRACT
This presentation will focus on where the industry is today and where machine
suppliers need realistic input from the OEMs for mass production needs. All
systems today are still based on prototyping equipment and in the integration
process to become reliable manufacturing systems. Hybrid and combined systems
are on the horizon: is this the future? Machines continue to get larger. Economicand entry barriers will be presented juxtaposed with new ideas along with the next
generation of systems.
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Keynote Speaker
Xinhua Wu
Monash University, Melbourne, Australia

Falcontech, Wuxi, Jinagsu Province, China
xinhua.wu@monash.edu
Biography
Prof Xinhua Wu is the founder Director of Monash Centre for Additive Manufacturing and
Director for ARC ITRH for high value manufacturing. She is Fellow of Australia Technology,
Science and Engineering and IoM3, UK and a world-leading expert in Ti alloys and in advanced
powder processing, in particular 3D printing of metals.
Prof Wu published over 120 refereed papers and is inventor to 12 international patents. She
organised 5 international conferences and edited 3 conference proceedings, gave about 30
keynote/invited lectures at leading international conferences.
In 2008 Prof Wu was awarded the Ti award by IoM3 for her outstanding record of world-class
research in titanium and its alloys. In 2014 she received the top innovation award and the jury
committee award from global aerospace giant Safran following several 3D printed components produced by her team that passed the engine test.
SELECTIVE LASER MELTING (SLM) OF AEROSPACE MATERIALS, ITS QUALITY

CONTROL AND CERTIFICATION
ABSTRACT
R. Chu, N. Perevoshchikova, J Mei, T. Jarvis, P Rometsch, D Tomus, R. Boyer and

J. Williams - Monash Centre for Additive Manufacturing (MCAM),
Selective Laser Melting (also called 3D printing) has been considered for aerospace and
biomedical applications where quality, consistency and repeatability are essential. This
presentation highlights the latest activities associated with Monash in terms of research
and development, powder production and the status in achieving international aerospace
certification for SLMd parts. Different materials, such as Al, Ti and Ni alloys have different
issues in SLM process, due to their metallurgical and crystallographic differences. Whilst
elimination of cracking and retaining high temperature properties are critical for SLM
Ni alloys, optimisation of post heat treatment becomes more significant for Al alloys as
defined by the nature of the sensitive response of precipitates of Al alloys during heat
treatment. Achieving aerospace certification requires controlling the quality from
powder to SLMd products and this is demonstrated here using Ti64 alloy. In order to achieve
current international aerospace standards for wrought products, 9 batches of powder
atomised from 3 lots of Ti bars, where each lot weighs >3 tonnes are used to SLM samples
using a laser powder bed system EoSM280. More than 3000 samples have been SLMd and
tested. It has been found that using appropriate quality of barstock followed by rigorous
control of the atomisation and SLM processes, outstanding mechanical properties coupled
with consistency and repeatability have been obtained in SLMd Ti64 parts and this has led to
the qualification of Falcontech Ti64 powder and SLMd parts for civil aerospace applications.
Some results in NDE will also be reported including the influence of shape of the defect and
depth on the minimum size of detects which can be detected using x-ray and synchrotron.
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Keynote Speaker
James Sears
Senior Mechanical Engineer, GE Global Research Centre,

Additive Manufacturing Laboratory, USA
Sears@ge.com
Biography
Dr. James W. Sears is also adjunct Professor for the Materials and Metallurgical
Engineering Department, and Professor for Bio-Medical Engineering at the
South Dakota School of Mines & Technology and Executive Director of the Quad
Cities Manufacturing Laboratory (QMCL), a not-for-profit research and development
company embedded within the Rock Island Arsenal - Joint Manufacturing and
Technology Center (JMTC).
Jim received his B.S. Mechanical Engineering Degree from University of Illinois (1981)
and while with Pratt & Whitney Aircraft, West Palm Beach, FL., he finished his M.S.
and in 1985 returned to University of Illinois for a Ph.D. in Mechanical Engineering
(1988). His research interests include additive manufacturing, rapid solidification
processing, powder metallurgy, plasma and laser processing, spray deposition and
fabrication with nano-particles. Jim has written over 80 published papers and holds
six US patents.
ADDITIVE MANUFACTURING: THE TRANSITION TO PRODUCTION WITHIN GE
ABSTRACT
GE Researchers have been developing new technology in additive manufacturing
for over 20 years. We see additive manufacturing as the next chapter in the industrial revolution. GE is committed to connecting with other innovators and growing
a global additive ecosystem to accelerate the growth of this emerging industry. GE
has a full-scale additive manufacturing facility in Cincinnati, Ohio, focused on the
development and scale up of new alloys, processes and parts for additive use. We
have a global team of several hundred manufacturing engineers at multiple sites
driving additive and other advanced manufacturing technologies. New ways to
make parts that will take performance to another level and bring together new
partners that change the way we work across the globe. Learn about what were
doingand more importantly, where were going will be discussed in this
presentation.
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Keynote Speaker
George Vicatos
Associate Professor at UCT, Mechanical Engineering

Director/Owner of ATTRI Orthopaedics, Capetown, South Africa
george.vicatos@uct.ac.za
Biography
Dr Vicatos obtained his education in England and received a BSc degree in Mechanical-Electrical
Engineering and a BSc degree in Marine Engineering from the University of Newcastle upon Tyne.
He also received an MSc degree in Aeronautics from Imperial College in London. He obtained his
PhD degree in thermodynamics with specialisation in absorption refrigeration from the University
of Cape Town. A life-long passion for medicine has led him to combine his Mechanical Engineering
skills with Bioengineering. Having studied Anatomy at UCT, the human skeleton and the soft tissues
have provided him with the foundation for designing and developing a large number of implants
for tumour suffering patients. His focus is on implants for limb-sparing surgery and on implants
that require complex surface development, such as the scapula and the pelvis. He has developed
modular implant systems for both the upper and lower limbs which have been used in more than
600 patients. He holds 8 patents for a range of medical devices.
Dr Vicatos current research focuses on improving the manufacturing processes for the implants and
identifying new technologies, choice of materials, treatment of articulating surfaces and osteointegration. His collaboration in research and development has linked him to academic institutions in
South Africa, UK and India.
TITANIUM DEPOSITION BY AM/SLS PROCESS ON THE SURFACE OF AN ANNEALED

MACHINED-COMPONENT
ABSTRACT
Titanium alloys have been accepted for many years as the choice materials for implants due to their
biocompatibility and their specific material characteristics as well as their ability to be treated with antibacterial agents. Besides the high strength, high endurance value in repeated loading and flexibility, titanium
alloys can also be surface treated to enhance osseointegration. Research shows that bone ingrowth is achieved
at surface porosity values of about 300 m and 600 m, while experiment for porous sizes less than 100
m, has shown that the there is no threshold porous value for new bone formation in the porous structures.
Recent research on 3D printed, scaffolding-like porous structures with porous size between 400-500 m [4], impregnated
with rat and human MSCs has shown in vitro that there is significant osteoblastic activity and calcium deposition on
base surface of the implant and on the strands of the structures. This is of particular importance as by using 3D printing
or AM processes, complete implants of complex geometries can be made, having surface structures that can enhance
bone ingrowth and accelerate osseointegration. However, 3D printing of large implants comes with high printing cost,
distortion of the dimensional reliability due to thermal stresses, and also it may need additional machining to bring it
to the designed dimensions. This may be overcome by printing only a small part which includes the osseointegration
surface and, if there is enough space, somehow to secure it on an conventionally-machined implant. This method has
merits, but on small implants it may be impossible to implement, due to dimensional limitations of the implant itself.
The current research shows that 3D deposition of structures on an already conventionally machined implant can
produce the desired effects of an implant with osseointegration surfaces. A slice through the thermally deposited titanium on the annealed substrate was polished, etched and examined by light-microscope and by electron
microscope. The deposited material is composed predominantly of alpha phase structures making a distinct interface
with the predominantly beta-phase substrate. There is no evidence of inclusions or voids at the interface and there
is a substantial diffusion of alpha-phase structures into the beta-phase substrate. It is to be further assessed that the
thermally deposited layers of the osseointegration structures do not distort the substrate and that dimensional integrity
is maintained. Biologically, it is expected that the alpha-phase of the deposited layers would support the same osteoblastic activity as observed during the in vitro investigation, and that it would allow treatment with antibacterial agents.
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Keynote Speaker
Ian Campbell
Loughborough University, Loughborough, UK

r.i.campbell@lboro.ac.uk
Biography
After graduating from Brunel University in 1985 with a BSc in the Special Engineering
Programme, Dr Campbell worked as a design engineer, first in Ford Motor Company,
and later in the Rover Group. Most of his design experience in both companies was
with internal combustion engines. In 1989, he was appointed as a Senior Teaching
Fellow for CAD/CAM at the University of Warwick. This gave him the opportunity
to raise his awareness of CAD/CAM technology and practices. He remained in this
position for four years, during which time, he undertook a part-time MSc degree by
research. In 1993, he obtained a lectureship at the University of Nottingham where
he was a member of the ground-breaking Rapid Prototyping Research Group, led
by Phill Dickens. His principle area of research was the integration of rapid prototyping into the design process and he gained his PhD on this topic in 1998. He moved
to Loughborough University as a Senior Lecturer in October 2000 and was made
a Reader in 2006. His publications include four edited books, over forty academic
journal articles and around one hundred other research outputs.
ADDITIVE MANUFACTURING AS A DRIVER FOR DESIGN INNOVATION
ABSTRACT
Additive Manufacturing (AM) has gained widespread recognition as a technology
that can make new things happen. The popular press and technical journals contain numerous examples of models, parts, products and artefacts that have been
made using AM, which otherwise would have been impossible or extremely difficult
to make. Such objects can be seen as innovations in their own right. However, the
deeper impact of AM upon innovation is in the new opportunities it is bringing to
designers. It is changing both the products that can be made and the relationships
that can exist between designer and consumer. This presentation looks at some of
the product innovations that have been enabled by AM and seeks to draw lessons
that will be of value to future innovators.
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Programme Overview
18
19
Pre-Conference Seminar on
Additive Manufacturing of Titanium Parts
Presented by Central University of Technology, Free State
Supported by the Department of Science and Technology
From its position as the worlds second largest producer of titanium raw
material, South Africa has the potential to add significant value to this natural resource.
Following on initial recommendations in the 1999 Mining and Metallurgy report of
the National Research and Technology Foresight Project, throughout the following
decade, a national consensus grew regarding this beneficiation opportunity. It
culminated in the development of a national Titanium Metal Industry Strategy by
the Department of Science and Technology (DST), and the establishment of the
Titanium Centre of Competence, as implementation vehicle of this strategy. Additive
manufacturing of titanium alloys was identified as one of the technology platforms
included in the Titanium Centre of Competence. In 2012, the need for a national
Additive Manufacturing plan was expressed by RAPDASA. In 2013, the DST
commissioned the development of a South African Additive Manufacturing
technology roadmap. This is intended to guide South African players in identifying economic opportunities, addressing technology gaps, focusing development
programmes and informing investment decisions that would eventually enable
local companies and industry sectors to become global leaders in selected areas of
additive manufacturing.
In response to the recommendations of the South African Additive Manufacturing
Technology Roadmap, a national Collaborative Program in Additive Manufacturing (CPAM) was conceptualised and presented to the DST for funding support by a
consortium consisting of the CSIR National Laser Centre, Aerosud, the Central University of Technology, Free State, Stellenbosch University, Northwest University, Vaal
University of Technology and the University of Cape Town. DST decided to fund the
program and it kicked off early in 2015.
Focus of the Seminar
In this 1-day seminar an overview of the CPAM sub-program on Qualification of
Additive Manufacturing of Ti6Al4V for Medical Implants and Aerospace Components
will be presented, followed by presentations on the progress made by the collaborating institutions. Postgraduate students from the participating universities will
present short papers on their research projects in support of this CPAM sub-program.
A keynote presentation on the production of titanium powder in South Africa will be
presented by Dr Dawie van Vuuren, Research Group Leader in charge of the CSIR-Ti
Pilot Plant.
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Tuesday, 3 November 2015
21
Wednesday, 4 November 2015

A South African AM Technology Showcase
Day 1 of the RAPDASA 2015 conference is dedicated to a South African Additive
Manufacturing Innovation Showcase. This day is different from the conventional
RAPDASA conference format in that the organising committee has decided to only
include invited presentations from leading South African innovators and entrepreneurs to present and showcase their innovative projects in the field of Additive
Manufacturing.
Additive Manufacturing, or 3D printing, is not only lead by research institutions
active in the field, but we have seen some inspiring stories from the local private
sector and also specifically local SMMEs who have seen the opportunities that
3D printing offers, and who have developed innovative processes, products and
services to address a specific requirement in the local and international markets.
The objective of this day is:

to introduce the RAPDASA conference delegates to some of the leading SA

innovators and entrepreneurs in this field

to give acknowledgement to these pioneers for the initiatives that they
have started and still continue to drive today

to bring innovative industries and local R&D activities at universities closer
together

to spark business creation opportunities in South Africa in the field of AM.
The day will end with a site visit to Aeroswift, a world leading South African
development program in the field of metal Additive Manufacturing.
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Wednesday, 4 November 2015
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Thursday, 5 November 2015
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Thursday, 5 November 2015
25
Friday, 6 November 2015
26
Friday, 6 November 2015
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Wednesday, 4 Nov 2015 Bateleur

FASTER, CHEAPER AND BIGGER 3D PRINTING TOWARDS A BIGGER MARKET
H. Fouch - Invited speaker

Fouch 3D printing, South Africa
hans@fouchechocolates.co.za
Abstract
What if....3D Printing can be faster and cheaper... by a factor of 100?
It started at Kentron, with helicopter and target drone projects of the day. A fascination with the pen plotters in the design office, and via model building requirements
in the wind tunnels of England. This story unfolds of 3d printing development, from
Superglue, to icing sugar, to chocolate, to plastic, to Polyfilla and to cement. And
that is not where it is going to stop! With speed and cost being the main drawbacks
of 3d printing, this paper looks at ways to make the process cheaper by a factor of
10, and by using cheaper material to 3d print with, and then to make it faster as
well, again by a factor of 10. There are some sacrifices to be made, but there is a lot
of applications where these methods can yield very good results. Fouch 3D Printing believes in the future of the big 3d printer. A machine that is 10 times faster, 10
times cheaper, and 10 times bigger than most machines can be a Game Changer?
We believe so!
28

INVENTION AND PROTOTYPING: ENABLING SMALL TO MEDIUM SCALE
MANUFACTURING ON THE CHEAP
Q. Harley - Invited speaker
Founder, Morgan 3D Printers, Centurion, South Africa

quentin.harley@gmail.com
Biography Quentin Harley
Quentin is an inventor and engineering technician with more than 20 years of
experience in medical robotics systems. In 2012 he started developing his own 3D
printer and won an international prize for the design of the Morgan printer. In 2015
he founded the Morgan 3D printers company that specializes in high quality low
maintenance robotic 3D printers, covering the mid to large build envelope spectrum.
Abstract
The talk will go over the merits of using low cost 3D printers in a small innovation company, and its value in the tool chain to manufacture high tech hardware.
The system can be used as a template to enable other small start-ups to arrive at
professional quality products at the lowest possible input cost.
29

MATURING FDM IN SOUTH AFRICA BY PROVIDING ENGINEERING FOCUSSED
MATERIALS, PRINTER PARTS AND CHEAP, CAPABLE PRINTERS.
Stephan Kotz - Invited speaker
Filament Factory, Roodepoort, South Africa

stephan@filamentfactory.co.za
Abstract
In the world of FDM printers, customers often become disillusioned when they cannot produce final parts with their current materials and machines.
Filament Factory has developed a range of products to assist customers in realizing
the full potential of FDM, from filament, to highly capable printers and accessories.
Our primary focus is to provide products that allow a customer to produce final parts
on their FDM printer. Along with these materials, we also provide accessories and
printers that enables the use of these materials. We also offer business opportunity
partnerships in filament manufacturing to lower distribution costs.
30
Notes
31
Notes
32
Notes
33
Thursday, 5 Nov 2015 Bateleur

MATERIALS & PROCESSES
REVIEWING ALLOY COMPOSITIONS FOR SELECTIVE LASER MELTING
Jan van Humbeeck - Invited speaker
(presented by Bey Vranken)

Department of Materials Engineering, Catholic University Leuven, Belgium
jan.vanhumbeeck@kuleuven.be
Abstract
Selective laser melting (SLM) applies powder compositions which are generally
produced by atomization of bulk materials. The composition of those powders was
selected in earlier times because they deliver the best properties after the required
classic processing, eventually including a post-processing heat-treatment.
Due to the extreme fast quenching from the extreme small melt pools during SLM,
very specific microstructures are formed. Those microstructures have been rarely
observed earlier but have a large influence on the microstructures obtained after
post processing heat treatments. As a consequence the after treatment (prescribed
for classic produced bulk materials, most of the time even normalized) when applied
on SLM-produced parts might not deliver the envisaged properties. Specific heat
treatments have to be developed in order to obtain the optimal envisaged properties (ductility, hardness) Moreover those new treatments can even lead to better
values of properties which could not be obtained before.
Apart from producing classic compositions, SLM offers also the possibility of
adapting or creating new composition through appropriate mixing powders of
different compositions. In some cases it can lead to better ductility, in other cases it
can avoid cracking of the parts during SLM processing without confining the final
required properties. Other possibilities will be the homogenous mixing of light
weight ceramic particles in (light weight) metallic alloys in order to strengthen the
matrix material and make it accessible for example to applications at high temperatures.
This lecture will illustrate some examples of new post-processing treatments and
describe the properties of a few materials with new compositions based on mixing
different powder compositions.
34

A COMPARATIVE REVIEW OFTHE MECHANICAL PROPERTIES OF SLM
PRODUCED Ti6Al4V
N.M. Dhansay and T.H. Becker
Department of Mechatronics and Mechanical Engineering,

University of Stellenbosch, South Africa
nurmdhansay@sun.ac.za, tbecker@sun.ac.za
Abstract
Selective Laser Melting (SLM) is an Additive Manufacturing (AM) process that has
gained significant interest in academia as well as industry over the recent years. Its
noteworthiness lies in the ability to produce geometrically complex metallic components for near end-use applications. One of the main concerns, however, when
utilising SLM produced components are their achievable mechanical properties.
What makes investigations intricate is that the mechanical properties of SLM produced components depends on numerous factors that include material powder
characteristics, a combination of the material and process parameters and postprocessing procedures. This research endeavours to compare the in literature
reported achievable mechanical properties of SLM Ti6Al4V produced using different
laser exposure strategies. Results suggest that the expose strategy has a considerable effect on the as-built components when compared to the same heat-treated
components.
35

CHARPY IMPACT TOUGHNESS AND PRIOR -GRAIN SIZE IN
TI6AL4V MANUFACTURED BY HIGH SPEED, HIGH-POWER (3KW)
LASER POWDER BED FUSION
D.F. Louw
CSIR National Laser Center, Pretoria, South Africa

dlouw@csir.co.za
Abstract
The build rate of a laser powder bed fusion machine can be increased by increasing
the laser power. The current paper shows that the use of higher laser power results
in a positive change in impact toughness of Ti6Al4V. Laser powder bed fusion is an
additive manufacturing technique that can produce functional metal components. The use of higher laser power is accompanied by an increase in scan speed.
Furthermore, a higher scan speed results in a faster solidification rate. During
processing of Ti6Al4V prior -grain size is proportional to solidification rate. In this
study prior -grain size of Ti6Al4V produced by high power laser powder bed fusion
is compared to Ti6Al4V processed by conventional low power machines. The subsize (55x10x2.5mm) Charpy impact toughness of Ti6Al4V produced in this study was
measured to be 8-10J which is higher than the 6J measured for Ti6Al4V produced by
low power laser powder bed fusion. This difference is discussed by comparing prior
-grain size of the two materials.
36

UNDERSTANDING OF SELECTIVE LASER MELTING: FROM NUMERICAL
SIMULATIONS OF THE PROCESS TO OPTICAL MONITORING
I.Yadroitsev1, I. Zhirnov2,3 and I. Yadroitsava1
Central University of Technology, Free State, South Africa

Moscow State Technological University Stankin, Moscow, Russia
3
Universit de Lyon, France
iyadroitsau@cut.ac.za, iyadroitsava@cut.ac.za and i.zhirnov@stankin.ru
1
2
Abstract
Selective laser melting (SLM) is an additive manufacturing technology which allows
the production of complex shape objects and fine structures in one cycle from metal
powders. Combination of advanced SLM technology with phenomenal properties of
modern alloys allows creating unique objects for medical, automotive and aerospace
industries. Since properties of SLM parts depend on the characteristics of tracks and
layers, optical diagnostics of the SLM process is an important issue. A high-speed
camera with CCD sensor and macro-lens was used for real-time visualization of the
track formation from powder particles during laser processing. To control the SLM
process, a simple method was proposed based on an infrared camera. Signals from
the IR camera were compared with numerical simulations.
37

REQUIREMENTS TOWARDS AM POWDER MANUFACTURES TO DESIGN
POWDERS FOR APPLICATIONS AND PROCESSES
Henner Schneborn
SLM Solutions Group, AG

henner.schoeneborn@slm-solutions.com
Abstract
Requirements to System Suppliers are to operate various and differed kinds of
powders and alloys from different suppliers, previously designed for different
technologies. AM Powder Bed equipment has the need to perform with any kind
of alloy(s) and powder(s). What are the challenges to the powder manufacturer and
the system suppliers?
The presentation will give an overview about the various types of machines and
powder characteristics which are used in the different types of machines and the
limits in both directions. The presentation is also to give an overview about the
various qualities of performance, if powders do not meet the specification with
regards to the appropriate equipment and material loop.
The presentation will outline the approach to design and/or modify powders to the
process and to adjust the process to the final required part performance.
38

EFFECT OF PROCESSING PARAMETERS ON POWDER DEPOSITION
EFFICIENCY OF THE OPTOMEC LENS
K. Malabi, M. Theron and J. Steyn

kmalabi@csir.co.za, mtheron@csir.co.za and jsteyn@csir.co.za
Abstract
The OPTOMEC LENS (Laser Engineered Net Shaping) is used to fabricate metal parts
directly from CAD (Computer Aided Design) solid models using a powder injected
into a molten pool. Lasers play an important role in the processing of materials used
in manufacturing and engineering industries.
This paper focuses on analysing the effect of processing parameters (scanning speed,
powder feed rate and laser power) on powder deposition efficiency in the 1 kW
Optomec LENS process through multiple layer build-ups. The powder deposition
efficiency of three powders was determined.
The highest powder deposition efficiency within the same parameter window was
obtained for Ti6Al4V, whereas Stellite-6 build-ups delivered the lowest powder
deposition efficiencies.
39

GEOMETRIC DEVIATION OF HYBRID PARTS PRODUCED BY
SELECTIVE LASER MELTING
D. Hagedorn-Hansen1, R. Cichon2, M.B. Bezuidenhout1,

P.A. Hugo1 and G.A. Oosthuizen1

Hochschule fr Technik und Wirtschaft, Dresden, Germany
19655630@sun.ac.za, 15124177@sun.ac.za, phugo@sun.ac.za, tiaan@sun.ac.za
and ramon.cichon@htw-dresden.de
1
2
Abstract
The utilisation of Additive Manufacturing (AM) for the production of intricate parts
in the aerospace, medical, and tool-and-die industries is continuously receiving
more interest. In the tool-and-die industry AM has been successfully used to integrate complex cooling channels inside injection and blow moulds. This results in a
significant increase in the production efficiency and quality of plastic products.
Moulds can typically be produced with better features when combining additive
manufactured using a combination of these processes are called hybrid parts. This
paper discusses the effects of the thermally induced residual stress on the geometric
deviation of hybrid parts with reference to simplified model parts produced from
wrought 1.2316 tool steel bases and CL50WS powder (1.2709). Also discussed are
possible methods that can be employed to reduce the effects of the thermal stress
on the deviation of the hybrid parts.
40

DIRECT METAL LASER SINTERED MULTI MATERIAL STRUCTURES
A. Kinnear, T. C. Dzogbewu, I. Yadroitsava

and I. Yadroitsev
Central University of Technology, Free State, Bloemfontein, South Africa

wakinnear@cut.ac.za, thydzo@yahoo.fr, iyadroitsava@cut.ac.za
and iyadroitsev@cut.ac.za
Abstract
Direct Metal Laser Sintering (DMLS), Selective Laser Melting (SLM), or Laser Cusing
is a powder bed fusion technology which is found in Additive Manufacturing (AM),
whereby a laser beam consequentially selectively fuses powder layers. Growth in AM
has produced the need for objects containing multiple materials for applications
in the medical, tool making, aerospace and other hi-tech industries. By applying
multiple materials, regions with different mechanical, thermal or corrosion
properties can be achieved in a single manufacturing cycle utilizing the DMLS
process. Using multiple materials on a medical implant has many advantages:
implant can be constructed to have different mechanical, physical and chemical
properties in prescribed areas of the implant. For example, a bone implant where the
middle section is made from a Ti6Al4V alloy and the outer part contains a coating of
copper, silver or other metals which have antibacterial properties. Also multi material
DMLS opens perspectives for producing implants with gradient mechanical properties applying different alloys to improve the functionality of the implant and reduce
stress shielding on the bone. These advanced implants combine different materials
allowing the implant to be more bio-compatible and increase the lifespan. With the
current DMLS equipment existing on the market, multi material objects are possible
but only with material differences between the layers. New approaches are needed
to develop methods that allow multi material objects to be produced not only in
the Z axis, but also allow material differences on a single layer (X-Y axis). In the study
the existing experimental methods for multi-material DMLS are analysed and an
original developed system is presented. Flowability of copper and Ti6Al4V powders
is described as the ability of powder to flow in a desired manner in an elaborate
depositing system.
41

DEVELOPMENT OF PROCEDURES FOR THE ACQUISITION OF
METAL ADDITIVE MANUFACTURING (AM) PARTS FOR USE
IN THE CSIRS WIND TUNNEL MODELS
C. Johnston
Experimental Aeronautics Research Group,

Aeronautics Systems Competency, DPSS, CSIR, South Africa
cjohnsto@csir.co.za
Abstract
The first Additive Manufacturing (AM) non-load-bearing, client furnished part was
used in the CSIRs wind tunnels in 2007. The advent of metal-grown materials, and
the acquisition of machines to grow them in South Africa, has made it feasible to
incorporate load-bearing parts in CSIR wind tunnel models. However, the safety
requirements for wind tunnel models are stringent, and the acquisition procedures
for wind tunnel models were revised. Lessons learnt from the manufacture of a
recent wind tunnel model are discussed. The AM technique demonstrates
advantages over traditional methods and further investigations will be undertaken.
42

SURFACE REFORMATION OF TITANIUM ALLOY (GRADE 5) AND COPPER
USING YTTERBIUM LASER SYSTEM: A REVIEW ON
MICROSTRUCTURE AND MICROHARDNESS
M.F. Erinosho1, E.T. Akinlabi1 and S. Pityana2
University of Johannesburg, Auckland Park Kingsway Campus, South Africa

mferinosho@uj.ac.za, etakinlabi@uj.ac.za and spityana@csir.co.za
1
2
Abstract
In additive manufacturing, powders have been deposited through various means
in order to form a specific dimensional solid. Laser Metal Deposition (LMD) is one of
the classifications of additive manufacturing. The light metal of titanium (Ti6Al4V)
alloy in large percentage weight is combined with heavy metal of copper (Cu) in
small percentage weight in order to reform the surface of the primary titanium alloy
using the LMD process on the Ytterbium laser system. However, the LMD processes
and the analyses of the modified Ti6Al4V-Cu alloys have been explored and reported.
The optimal settings from the responses in the design of the experiment were considered for the deposition process, and analyses were conducted on the evolving
microstructures and microhardness of the laser deposited alloys. The microstructures of the reformed alloys revealed a crack-less with no porosity. Basket weave-like
Widmanstettan structures were formed in the -phase and -phase regions of the
Ti6Al4V-Cu alloys. The microhardness of the reformed-deposited Ti6Al4V-Cu alloy
of sample FF deposited at a laser power of 1.600 kW and a scanning speed of 0.59
m.min-1 exhibited the highest value of 443 HV0.5. An increase in scanning speed
and the alloying element (Cu) was observed to have an influence on the hardness
values. However, the reformed-deposited Ti6Al4V-Cu alloy can be utilized in marine
industries to combat the problem of biofouling.
43
Notes
44
Notes
45
Thursday, 5 Nov 2015 Fish Eagle

DESIGN
SIMULATION-DRIVEN DESIGN AND ADDITIVE MANUFACTURING
U. Schramm - Invited Speaker
Altair Engineering, Inc., Irvine, CA, USA

schramm@altair.com
Abstract
Additive manufacturing has a long history. In recent years certain additive
manufacturing technologies have gained new attention. This is mostly driven by the
need for light weight design, mass customization, as well as rapid manufacturing.
The promise of additive manufacturing is form freedom, complexity made easy, individualized products, and accelerated production.
On the other hand there has been a shift in how products are designed. More and
more design processes are driven by the use of computer simulation rather than
physical experimentation. Technologies like Finite Element Analysis (FEA) and
Computational Fluid Dynamics (CFD) have been transformed from being purely used
for product validation and failure mode analysis to being design tools. In particular
a FEAbased technology called Topology Optimization has emerged as a powerful
simulationbased design tool. Topology Optimization uses load information to derive the optimal material layout for light weight design. These designs have a very
aesthetic look and remind us often about biological designs.
There seems to be a natural symbiosis between simulationdriven design and
additive manufacturing. Often the true optimal design cannot be manufactured
with other means like casting, forging, milling, or extrusion. Then manufacturing
constraints have to be introduced in the concept phase of the design where topology optimization is used. With additive manufacturing, there are less such
constraints and the manufactured part can be closer to a theoretical design
optimum.
The note will review these aspects of design for additive manufacturing. Many
examples will be shown where simulationdriven design leads to innovative shapes
and more efficient structures.
46

DESIGN
ADDITIVE MANUFACTURING AN ENHANCED NEED FOR SYSTEMS DRIVEN
PRODUCT DEVELOPMENT
A. Berndt and C.J. van Schalkwyk

ESTEQ, Pretoria, South Africa
c.vanschalkwyk@esteq.com
Abstract
Additive Manufacturing (AM) is an exciting technology which has matured enough
to be used in the design cycle of components used in regulated industries i.e.
Automotive, Aerospace and Utilities. The multiple benefits of AM include:
complex geometrical shapes,
reduced component counts (fabricated assemblies can be replaced with single
components),
systems that could not be assembled with traditional methods.
The idea that designs are driven more by functional aspects than their manufacturing requirements makes AM attractive. In a world where lower cost, lower weight
and greater efficiency are always sought after, AM promises to deliver great value.
However, there are always tradeoffs involved. Designs that are driven by
functional considerations often tend to be optimized, with a proportional reduction
in robustness. AM technology and the ability to produce optimized designs places an
increased burden on the designer to understand the system and operating environment in which the AM component has to function. Successful use of AM technology
requires a high level of engineering competence in the fields of structural mechanics, material behaviour, loading and failure mode prediction. In addition, engineers
will be required to perform an increased number of physical tests: material coupon
testing, fatigue testing, modal testing etc. until the AM process is as well understood as traditional methods. Systems Driven Product Development, a development
philosophy implemented by best-in-class companies, has been very successful in
managing the complexities of modern product development. Systems that are
managed from requirements definition, cascaded down through to the design of
the lowest-level components, with validation and verification cascaded up to prototyping and realization, are truly successful in addressing real-world product development projects. The opportunities of AM and the additional engineering complexity
inherent in the optimal application of this technology underscores the need for a
systems driven approach to product development.
47

DESIGN
DESIGN AND OPTIMIZATION PROCESSES FOR ADDITIVE MANUFACTRUING
J.L. Serfontein
Senior Stress Engineer

Engineering Analysis and Simulation Department
Aerosud Aviation, Pretoria, South Africa
jp.serfontein@aerosud.co.za
Abstract
With additive manufacturing technology maturing from the primary use of
prototyping to a high level manufacturing method, the design process for additive
manufacturing has been investigated. The goal of the research was to evaluate the
capabilities of various Computer Aided Design (CAD) and Computer Aided Engineering (CAE) software packages and how these tools can be used to complete a
design cycle. CAD software used in the design process was facilitated by a number
of products: Dassault Systmes Catia V5 with support provided by Intrinsys, PTC Creo
with support provided by ProductOne, Solid Thinking Evolve with support provided
by Solid Thinking and Altair, and Siemens Nx with support provided by Esteq. CAE
software used in the design process was facilitated by several products: MSC Patran/
Nastran, Nx Nastran with support provided by Esteq, Altair HyperMesh with support
provided by Altair, and Solid thinking Inspire with support provided by Altair and
ProductOne.
Two design philosophies were approached with the goal of attaining new
components. Using the optimization methods available in the CAE packages a
current component design (CCD) and a designated volume design (DVD) are
optimized with the goal of reducing their respective weights while maintaining
specific stiffness and strength requirements. The geometry attained for the CCD
yielded results where the components could still be manufactured using traditional
methods as well as additive methods. However, the geometry attained for DVD is
only manufacturable using additive methods.
48

DESIGN
DESIGN CONSIDERATIONS AND CONSTRAINTS FOR ADDITIVE
MANUFACTURED PRODUCTS
M.J. Hart
Sensor Science Technology/Material Science and Manufacturing,

Council for Scientific and Industrial Research, Pretoria, South Africa
jhart@csir.co.za
Abstract
MultiCAM is a multi-spectral corona inspection camera for the use of detecting
electrical faults on high voltage transmission lines. Corona is a phenomenon that
results from the ionizing of air due to the presence of high electric or electrostatic fields. Around 400 various corona cameras have been sold globally since 2008
ensuring a gross income of about R160 million to South Africa. The majority of these
cameras utilize the SLS additive manufacture process as the packaging alternative to
injection molded housings.
This paper will look at a number of considerations when designing high end
products with low to medium quantities. Factors like product cost, ergonomics,
aesthetics, functionality and quality needs to be addressed to ensure acceptance
in an ever growing competitive world. Additional influences to consider include
accurate model integration, manufacturing processes, tolerances, assembly
techniques and product development time.
49

DESIGN
DESIGN THROUGH TOPOLOGY OPTIMIZATION FOR ADDITIVE
MANUFACTURING: CHALLENGES AND SUCCESSES
Uwe Schramm1, Ming Zhou1, Michael Bogomolny1,

Raphael Fleury1, Gronum Smith2
Altair Engineering, Inc., Irvine, CA, USA

Altair Engineering S.A. (Pty) Ltd, Stellenbosch, South Africa
schramm@altair.com and agsmith@altair.co.za
1
2
Abstract
Topology optimization can help engineers to think out of the box during
early stage of concept generation. It can generate surprisingly efficient designs in
engineering fields where products are already considered highly sophisticated.
For example, applying topology optimization Airbus achieved over 40% weight
reduction on a group of A380 leading edge ribs. Since topology optimization
often creates free-forming bionic structures, interpretation of design concepts that
fits traditional manufacturing methods has been a challenge. 3D-Printing brings
almost unlimited freedom for design shape and form, hence offers the perfect
combination with topology optimization for creation of most efficient structures.
50

Community & Education
IDEA 2 PRODUCT LAB INTERNATIONAL STATUS AND SUCCESSES
D.J. de Beer1, M. van Tonder2, J.H. Jooste2, O. Diegel3,

R.I. Campbell2, D. Prawel4, I. Gibson5, F.R. Bezuidenhout1and
A. Du Plessis6.
North West University, Potchefstroom, South Africa

Vaal University of Technology, South Africa
3
Division of Product Development, Lund University, Sweden.
4
Colorado State University, United States of America.
5
Deakin University, Australia
6
Stellenbosch University, South Africa
deon.debeer@nwu.ac.za, malanvt@vut.ac.za, jhj@vut.ac.za, olaf.diegel@design.lth.se,
r.i.campbell@lboro.ac.uk, david.prawel@colostate.edu, ian.gibson@deakin.edu.au,
frederick.bezuidenhout@nwu.ac.za and anton2@sun.ac.za
1
2
Abstract
Following on the establishment of the Fablab initiative in South Africa, the Idea 2
Product (I2P Lab) initiative was introduced at the VUT during 2011 and officially
presented during the 2011 RAPDASA Annual International Conference. The I2P Lab
initiative was aimed at introduction to and facilitation of access and education
to CAD and AM to the wider community to lead to democratization of AM.
Due to its very logic and practical orientation, the I2P Lab initiative immediately
gained acceptance by leading local and international institutions and various labs
were established in SA and abroad. The paper will report on local and international
successes achieved in the roll-out of I2P Labs and achievements as regards to
education (school, university and individual/industry skills development and user
successes). Various future models will be presented as a possible road map to
further support the future democratization of AM.
51

THE UJ ENERGY MOVEMENT: LIGHTWEIGHT ALTERNATIVE
ENERGY VEHICLES - 3D PRINTING
W. Hurter
Sustainable Energy Technology and Research Centre (SeTAR),

The University of Johannesburg, Johannesburg, South Africa
warrenh@uj.ac.za
Abstract
The third UJ Solar Car was designed and manufactured by a group of post graduate
and undergraduate students from the University of Johannesburg to compete in the
2014 Sasol Solar Challenge. 3D printing technology was used throughout the vehicle
in order to create lightweight, functional parts. Such parts include a unique steering
wheel design which combined the skills of an industrial designer, mechanical engineer and electrical engineer, as well as being able to vastly reduce the overall weight
of custom designed Lithium Ion battery packs for the vehicle.
52

THE UTILISATION OF CAX TECHNOLOGIES IN THE MANUFACTURE OF
PAPER MACHE MOULDS FOR USE BY COMMUNITY CRAFT
ENTERPRISES IN SOUTH AFRICA
M. Bolton
University of Johannesburg, South Africa

mbolton@uj.ac.za
Abstract
This paper aims to illustrate the effective utilization of rapid prototyping and
Computer Aided Design technologies in the development and manufacture of low
cost plastic moulds for use by two Government Funded community paper making
projects in South Africa. This is for the manufacture of craft sculptural products made
from paper pulp and natural plant fibers. The process which was followed in the
manufacture of these moulds includes the utilization of freely available 3D Scanning
Software, CAD software packages, CNC subtractive rapid prototyping technologies
and plastic vacuum forming to create resin tooling. This tooling was used to manufacture thirty mould sets which were ultimately handed over to two paper-making
co-operatives.
53

LIBRARY MAKERSPACE - MAKING IDEAS A REALITY
I. van der Walt
DLS: Strategic Innovation, University of Pretoria, South Africa

isak.vanderwalt@up.ac.za
Abstract
The MakerSpace at the University of Pretoria is the first educational MakerSpace at a
higher education institution in SA. The MakerSpace provides a social platform where
students from various disciplines can come together to share their ideas, knowledge
and skills. Collaboration is the key driver of the space but it relies on regular and easy
access to various tools and features. Tools in the MakerSpace differ by application and
location but the University has fairly generic tool set such as 3D Printers, 3D scanner,
Intel and Arduino electronics and various other tools and refinement equipment. The
space allows students to approach their projects and ideas with peace of mind that
there will be someone to assist them along the way. One of the main features in the
MakerSpace is the access to three 3D Printers. These printers allow students to, at a
low cost, do rapid prototyping of their ideas and projects. To date the availability of
3D print services has seen the adoption and application thereof rapidly increase not
only by students but by faculties as well. The presentation will cover what the Maker
movement is, how the space was established, tools and services available and lastly
an overview of completed projects and events hosted.
54

PRODUCTION OF A RAT DISSECTION MODEL UTILISING COMPUTER
TOMOGRAPHY AND ADDITIVE MANUFACTURING
J. Els1; L. Kok 2 and E. Vercuiel 3

Anatomoulds (Pty) Ltd, South Africa
3
Animal Ethics Unit, National Council of SPCAs, South Africa
jels@cut.ac.za
1
2
Abstract
Rats are commonly dissected to teach basic anatomy at primary and secondary school level as well as University level. This necessitates a large number of
animals, in particular rats, to be euthanised each year. This practice is considered
unacceptable by animal welfare groups and an alternative teaching aid needs to be
found. With the aid of specialised software, Computer Tomography (CT) scan data
can be translated into a format that is printable through additive manufacturing
processes. A CT scan of a rat was used to design a teaching aid that includes all major
anatomical landmarks. The model was printed by means of Selective Laser Sintering
(SLS) in PA2200 Polyamide. The printed components were hand finished to improve
their appearance and used to cast a master mould in a platinum cure silicone. This
master mould was then used to cast multiple copies of the model in a silicone rubber.
55
Notes
56
Notes
57
Thursday, 5 Nov 2015 Cormorant

Business
NEW INDUSTRY PRIORIZATION WITHIN IDC
B. Strydom - Invited Speaker
Senior Project Development Manager

New Industries SBU, the Industrial Development Corporation,
Sandton, South Africa
berties@idc.co.za
Abstract
The Industrial Development Corporation (IDC) has refocused its business with
effect from 1 April 2015. As part of the refocus the Venture Capital SBU has been
incorporated into the newly-formed New Industries SBU. The New Industries SBUs
vision is to establish new industries that will form the base of the South African
economy of the future. We will do so by pro-actively identifying the most promising
new and emerging industries/technologies, and then supporting and nurturing them
until they have become globally competitive and self-sustainable. We will target new
industries that have the potential to make a significant contribution to economic
growth in the country. These new industries will stimulate jobs-rich industrialisation
through increased local manufacturing and further beneficiation of South African
resources.
We have analysed 22 candidate new industries from the perspective of attractiveness (significance of impact on South African economic growth) and South
African competitive advantage (probability to succeed). Industry attractiveness was
assessed against both sustainability and developmental impact considerations.
Of the 22 new industry candidates, 7 have been prioritised for pro-active
development. Additive Manufacturing is one of these however, it is not actually
considered as a new industry, but rather an enabling technology.
New industry assessment and prioritisation will however be a continuous process
and as a result other new industry candidates may be prioritised in subsequent years.
58

Business
SOCIAL MANUFACTURING BUSINESS MODEL ELEMENTS TO SUPPORT
LOCAL SUPPLIERS
C.I Ras1, J. Botes1, M. Vermeulen1, G.A. Oosthuizen1 and

J.W. Uys5
University of Johannesburg, South Africa
16452550@sun.ac.za, 16496698@sun.ac.za,
tiaan@sun.ac.za and jw.uys@fnb.co.za
1
2
Abstract
Manufacturing systems change constantly and new theory toward value creation is
emerging.
Recent manufacturing strategies have been initiated on a national level such as the
NNMI (US), Catapult (UK), Industry 4.0 (Germany) and SIP (Japan) to create value
from these adjustments. Similar to the open source information revolution, open
design platforms could eventually put the means to produce physical objects in the
hands of every individual. In the last decade we have witnessed some new emerging
approaches to technology creation and transfer. Nowadays, within this wave of
the Internet of Things (IoT) the innovation process is even totally opened to global
communities in which everybody can participate. Everybody can access and use
existing design tools and solutions on these platforms and co-create even more
solutions. This paper investigates the changes in societal needs, market, business model and enabling technologies of the different manufacturing paradigms.
Thereby, focusing on social manufacturing the business model of several innovative
manufacturing companies is explored and the effects of social manufacturing on
rapid product development discussed to support local suppliers.
59

Business
PLATFORMS FOR ADDITIVE MANUFACTURING ENTERPRISE DEVELOPMENT IN
SOUTH AFRICA, CREATING AN ECOSYSTEM FOR ADDITIVE MANUFACTURING
WB du Preez
Department of Mechanical and Mechatronics Engineering

Central University of Technology, Bloemfontein, South Africa
wdupreez@cut.ac.za
Abstract
Additive manufacturing (AM) has been described by some as the next phase in the
industrial revolution. In Europe it has been recognised as a key emerging manufacturing technology, while others believe it is likely to revolutionise business in
coming years. In the USA the initiative endorsed by the president, America Makes,
also known as the National Additive Manufacturing Innovation Institute (NAMII),
demonstrates their national will to drive this kind of manufacturing. The China 3D
Printing Technology Industry Alliance forms part of the Chinese governments plans
to support AM. Big international industry players have become involved in pushing AM to the next level and, consequently, have put their reputations on the line.
Indications are that the pace of AM will pick up, which would lead to a jump in
the adoption rate of AM by industry. However, it is also becoming clear that new
business models will have to be developed to make the most of the disruptive
power of AM. Instead of just relying on organic growth through multiplication of small
makers, the largest industrial impact would most probably be achieved through
the establishment of digital, manufacturing, business development and marketing
platforms focused on AM. In this paper the concept is discussed of an integrated,
holistic platform, encompassing industry, R&D institutions, academia, government
and financial investors, as vehicle to support AM enterprise development. Strategic
considerations, such as alignment with established national priorities and needs,
redesigned offerings, re-optimised operations, concurrent engineering and
reconfigured ecosystems, form the fundamental thinking behind this concept.
It would provide benefits such as sustainable linking of the R&D community with
industry, sharing costly infrastructure, access to best practices in design and
optimisation, flexible, versatile AM production, as well as novel business and
marketing models. The role of existing associations and programmes, such as
RAPDASA and the Collaborative Program in Additive Manufacturing, pro-active
industry players and national initiatives that could contribute towards realising such
platforms, is unpacked. A case is made regarding the imperative for South Africa of
establishing such an environment to improve the competitiveness of its manufacturing industry, which should result in economic growth and sustainable job creation.
In conclusion, thoughts on an approach towards implementing such a concept are
shared.
60

Business
ADVANCED MANUFACTURING TECHNOLOGY IMPLEMENTATION: AN EXAMINATION OF ORGANIZATIONAL FACTORS
I.A. Khota 1,2, J. Knock 2
Industrial Development Corporation, Sandton, South Africa

Gordon Institute of Business Science; University of Pretoria, South Africa
irfaank@idc.co.za and jasonivoknock@gmail.com
1
2
Abstract
Amid increased competition associated with globalisation, the South African
manufacturing sector has come under increased pressure in recent times, with an
associated decline in competitiveness. There has been a strong drive by
organisations to invest in innovations in the form of Advanced Manufacturing
Technologies (AMTs) in an effort to improve their technological status and
performance. While investment in AMTs often has a positive impact on performance, numerous accounts of the AMT not meeting expected benefits have been
reported. Inability to effectively extract intended benefits from the AMT is often a
result of the complex nature of the process, which requires technological considerations and a strategic approach. The objective of this research was to identify the critical
organisational factors that impact AMT implementation and establish the relative
importance of the factors to provide a guide to managers implementing AMTs
to prepare their organisations for the new technology and extract the intended
benefits. The research took the form of a quantitative study guided by a
self-developed survey and was carried out on manufacturing organisations
operating in South Africa. The survey put forward a set of four critical factors that
impact AMT implementation, each defined by a proposed set of sub-factors that were
validated as accurate definitions in the research. The research established the
importance of the proposed factors in contributing to effective AMT
implementation, with top management ability and training and education ranked
highest, followed by organisational ability a level below and incentives and rewards
occupying the lowest level of importance. The importance of these factors was
validated through a correlation established between AMT implementation
success and the degree to which the organisational factors are evident within an
organisation. Organisational readiness of manufacturing companies in South Africa
to effectively implement AMTs was also assessed. AMT Considerations related to the
size of the organisation and the type of AMT being implemented are also presented
along with a summary of key benefits targeted from AMT implementations. Findings
were used to develop a model that presents a guide to highlight areas that need
attention within an organisation to assist in the allocation of resources during AMT
implementations.
61

Tooling
APPLICATION OF ADDITIVE MANUFACTURING FOR PERFORMANCE
IMPROVEMENT OF TOOLING IN MOULDING AND SHEET METAL FORMING
PROCESSES: A REVIEW
R Muvunzi 1, D Dimitrov 1, S Matope 1 , C Kufazvinei 2
Stellenbosch University, Stellenbosch, South Africa.

University of Technology, Chinhoyi, Zimbabwe.
rumbimuvunzi@gmail.com, dimitrov@sun.ac.za, smatope@sun.ac.za, and
chris.kufazvinei@gmail.com
1
2
Abstract
The paper gives an insight of AM processes that have been applied in the tooling
industry to improve performance of moulding and sheet metal forming processes.
Advantages and challenges gained in the use of AM as compared to the conventional tooling have been mentioned. The RT and RM processes used in moulding
and sheet metal forming have been highlighted including their shortcomings. The
paper also presents some potential areas of application in which AM technologies
can be further manipulated to improve tool performance. Lastly, a discussion has
been made on current issues associated with the use of AM in tooling.
62

Tooling
AN INVESTIGATION INTO CONFORMAL COOLING OF ALUMIDE MOULDS IN
PLASTIC INJECTION MOULDING
K.D. Mosimanyane 1, G.J. Booysen 2 , J.G. van der Walt 3
1,2,3
Department of Mechanical and Mechatronics Engineering
Central University of Technology, South Africa
1
kmosiman@cut.ac.za, 2 gbooysen@cut.ac.za and 3 jgvdwalt@cut.ac.za
Abstract
In product development nowadays it is often necessary to manufacture small
quantities of functional plastic parts to validate design functionality before mass
production. It is during this stage of development where Rapid Tooling (RT) is
considered, as it is quick to manufacture and less expensive compared to
conventional tools. In this study a rapid tool is produced using Alumide as a
tooling material. Alumide can be processed on Additive Manufacturing (AM)
machines such as the EOS P385 machine. Alumide melts at 170C to 180C
making it difficult to withstand injection temperatures of polymers during plastic
injection moulding. This paper will showcase results from simulating (using Sigmasoft)
cooling inside Alumide inserts that was also verified through actual experiments.
To measure the temperature inside the Alumide inserts, probes were inserted at
specific points in the inserts and temperatures were logged in Lab View through a
Data Acquisition (DAQ) device.
63

Tooling
RAPID TOOLING APPLICATION FOR THE EVALUATION OF A
GREENSAND CASTING DEFECT
J.W. de Beer , K.D. Nyembwe
Department of Metallurgy, University of Johannesburg, South Africa

justindb@uj.ac.za, dnyembwe@uj.ac.za
Abstract
The ability to produce production quality tooling, directly from CAD data, through
additive manufacturing (AM) processes has obvious advantages with regards to the
reduced lead time and labour costs. This, together with the ability to simulate the
metal casting process, opens new doors for researchers in the field of metal casting.
This paper reviews the suitability of tooling produced in PA 2200 polyamide material,
for use in a research environment, where the failure of greensand, a mixture of silica
sand, bentonite (clay) and water, is to be replicated as it would occur in an industrial
setting.
64

Tooling
A COMPARISON OF ADDITIVE MANUFACTURING TECHNOLOGIES
FOR INVESTMENT CASTING PATTERNS
T. Mueller
Voxeljet, Friedberg, Germany

tom.mueller@voxeljet.com
Abstract
Over the last two decades, a number of AM methods have been developed to print
patterns for investment casting. Currently, four technologies account for the vast
majority of use. In this investigation, those four technologies are compared, both in
the casting performance of the patterns they create, and in the cost and productivity
of the machines that create them. In addition, the market for investment castings is
examined to identify opportunities for printed patterns beyond prototyping.
65
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67
Thursday, 5 Nov 2015 Barn Owl

Exhibitors
MATERIALISE: SOFTWARE SOLUTIONS SUPPORTING YOUR WORKFLOW
FROM DESIGN TO PRINTED PART
J. Goossens
Materialise NV, Leuven, Belgium

jeremy.goossens@materialise.be
Abstract
With its headquarters in Leuven (Belgium) and branches worldwide, Materialise has
been playing an active role in the field of Additive Manufacturing (AM) since 1990. In
addition to having the largest capacity of AM equipment in Europe, Materialise also
enjoys a stellar reputation as a provider of innovative software solutions. Materialise
has developed unique solutions that make a world of difference for its many customers with their prototyping, production and medical needs.
Materialise started as a specialist in Rapid Prototyping (RP) and Additive
Manufacturing (AM). From there on they grew into the market leader for 3D
printing and digital CAD software. Materialise has a stateoftheart AM
facility with numerous technologies, which has allowed our team to become industry
experts. With firsthand knowledge of all the technologies and bottlenecks in AM, our
software development staff the largest in the sector stays ahead of the trends. We
provide software solutions for every step of the AM process, from design to printed
part, as well as solutions for 3D printers varying from the smallest to the largest.
Together these solutions form a software platform for 3D printing which links
applications from various markets and industries, ranging from automotive,
aerospace, medical industry, consumer goods and many more to the wide range of
3D printers and Additive Manufacturing technologies.
During the presentation Materialise will share some business cases and share insights
on projects where they provided process optimization, application specific software
developments and software solutions assisting their customer throughout each step
of the Additive Manufacturing process, from the conceptual phase to improving
the design, to datapreparation, direct integration with the machine, managing and
controlling the entire process to shipping out the parts to the customers. Materialise
offers a neutral and performant software platform which can be customized to the
specific environment and requirements of the user, being it data preparation tools,
advanced lattice generation design software, full process planning and control tools,
offer full traceability of your produced parts, custom software development, provide
supporting software for hardware manufacturers Materialise is here to provide the
necessary tools to take your Additive Manufacturing activities to the next level.
68

Exhibitors
THE APPLICATION OF ADDITIVE MANUFACTURING WITH FDM TECHNOLOGY
BY SOUTH AFRICAN COMPANIES
R. Oosterlaak
3D SOLIDS AMT, Pretoria, South Africa

proosterlaak@3dsolids.co.za
Abstract
The application of Stratasys FDM (Fused Deposition Modelling) technology by South
African companies to produce end-use parts, jig tools, fixtures and foundry patterns.
The presentation will show Additive Manufacturing technology across a wide range
of industries. This includes product design, jig tools and fixtures in the engineering,
aerospace and automotive industries. Low volume production of plastic components in the aerospace, automotive, plastic converters and general engineering use.
69

Exhibitors
DESIGN FOR AM - SOFTWARE SOLUTIONS AND CASE STUDIES
Dave Bullock
Rapid3D
david@rapid3d.co.za
Abstract
Design to fully exploit the power of AM requires software tools and techniques
that facilitate and enable the creation of forms and structures. Rapid 3D has been
involved with several very interesting and challenging projects over the years that have
required lateral approaches to achieving solutions. In the process we have gained
experience in a wide range of hardware and software solutions. Often it is not
possible to use a single software tool or prototyping technique to achieve the end
goal. This experience will be shared and illustrated using case studies.
70

Exhibitors
3D PRINTING: TURN HYPE INTO INDUSTRIAL MANUFACTURING SOLUTIONS
Peter Rosker
EOS - Gmbh
peter.rosker@eos.info
Abstract
3D printing, or additive manufacturing, has in fact been in use since the 1980s.
But it has only recently come into mainstream use. More and more companies are
using AM for production of parts, replacing tradional manufacturing technologies
like casting or milling.
Especially Aerospace is a great supporter of emerging technologies, and large
aerospace companies and supply chains have already started to use AM as a means
to manufacture airframes and engine components.
The present paper provides an overview of the challenges the technology is
facing and the hurdles to overcome in order to deliver processes and systems suitable
for the production environment, focusing on critical industries like aerospace and
medical.
71

Exhibitors
IMPACT OF THE VUT SOUTHERN GAUTENG SCIENCE AND TECHNOLOGY
PARK ON LOCAL COMMUNITY AND INDUSTRY
L. Becker, H.L. van der Merwe, J. Molete
Vaal University of Technology, Sebokeng, South Africa

leslieb@vut.ac.za, hendrikv2@vut.ac.za and josephm2@vut.ac.za
Abstract
The VUT Southern Gauteng Science and Technology Park (VUT STP) was
mandated to uplift the local community by means of teaching, learning and
research. In the beginning, the VUT STP pioneered the Advanced Manufacturing
Precinct (AMP). The AMP offered services in the field of Design, Development,
Additive Manufacturing, CNC Robotic milling, CNC milling, Mould Design and
Manufacturing, Specialised Training directly to the community in the form of the I2P
and Fab-Lab, Transfer of knowledge by means of TIA and DTI projects, workshops,
conferences and assistance to students and industry. Industry involvement as part
of the quadruple helix philosophy applied in learning new application of technologies that encompass, disruptive technologies, new advanced materials, alternative
methods and gaining knowledge from failures too. The VUT STP endeavoured
to be the nexus of technology support and also a vehicle to uplift the local
community. Training, incubating, nurturing entrepreneurs and the development
of sustainable enterprises formed the foundation of support. Partnering with local
and international companies spearheaded the Industrialisation programme at the
STP. These partnerships strengthened the ability to learn, teach and improve the
potential for research deliverables. The type of industries involved varies from
design for advanced manufacturing, aerospace, agriculture, foundry, mechatronics,
footwear, medical, renewable energy, to education and so forth. The impact of the
vision will be measured by the goals set for the next five years. Some of the goals
include the creation of 1000 professional jobs, support 400 start-up businesses,
production of 600 projects to working prototype stage and numerous community
initiatives. The ultimate goal is to impact the local and international communities.
72

Exhibitors
THE NEW CONNEX 3 MULTI-COLOR MULTI-MATERIAL POLYJET
PRINTER FROM STRATASYS
Jacques Kleynhans
Demaplastech
jacques@demaplastech.co.za
Abstract
Bring new production-floor efficiencies to fruition with in-house tooling, custom jigs,
assembly fixtures and gauges. With triple-jetting technology, hundreds of Digital
Materials, and two spacious build-tray sizes, Connex3 is your product development
and production powerhouse.
Get unmatched versatility with a range of material properties from rubber to
rigid, transparent to opaque, neutral to vibrantly colourful and standard to biocompatible. For jobs that require a range of mechanical, optical or thermal properties,
only Connex3 lets you combine up to three base resins in pre-set configurations to
produce up to 82 materials in a single build.
3D print jigs, fixtures and tooling even short run injection moulds, blow moulds
and sandcasting patterns to exacting specifications with 16-micron layer thickness and smooth surfaces right off the print tray. Create ergonomic, multi-material
tools with non-slip grips, rubberized product-facing surfaces, crisp print and colour
coding directly from the digital file. With Connex3 on your manufacturing floor, youll
be more agile than ever.
73

Exhibitors
CENTRE FOR RAPID PROTOTYPING AND MANUFACTURING
Johan Els
Centre for Rapid Prototyping and Manufacturing

jels@cut.ac.za
Abstract
The Centre for Rapid Prototyping and Manufacturing (CRPM), at the Central
University of Technology, Free State in Bloemfontein, is a dedicated Additive
Manufacturing (AM) centre which focuses on research on medical implants and also
delivers commercial work for both national and international clients.
The research on medical implants has provided invaluable knowledge on AM in
metals and particularly titanium, which in turn has benefited those patients in State
hospitals unable to pay for life-changing surgery.
CRPM can offer high quality products to the manufacturing and medical sectors with
the various machines available at the centre. This presentation will highlight the
work carried out in the centre and the services available.
74

Exhibitors
PRODUCT DEVELOPMENT TECHNOLOGY STATION OFFERINGS
L. Barnard
Product Development Technology Station

Central University of Technology, Bloemfontein, South Africa
lbarnard@cut.ac.za
Abstract
The Product Development Technology Station (PDTS) is located at the Central
University of Technology, Free State in Bloemfontein. PDTS is partly funded by the
Technology Innovation Agency (TIA). The aim of PDTS is to help SMEs to become
more competitive through the development of new products or the changing of
processes.
PDTS has five main focus areas which are: Enclosure design and development,
Reverse engineering, Limited run tooling, Conformal cooling in tool inserts and
Machine building. PDTS offers its services to the general public as well as small- and
large companies. In this presentation, examples of projects completed at the station
will be discussed to demonstrate the services offered by PDTS.
75

Exhibitors
INNOVATIONS WITH METAL 3D PRINTING SINCE 1996 WITH SLM SOLUTIONS
A. Belaid
SLM Solutions GmbH, Lbeck, Germany

amed.belaid@slm-solutions.com
Abstract
Since 1996 the team of the todays SLM Solutions GmbH, Germany (former MCP-HEK
Tooling GmbH and MTT Technologies GmbH together with F+S Stereolithography
GmbH) is defining technology trends in Direct Metal 3D Printing for powder bed
machines, even though Metal Sintering was established some years before.
The speech will give an overview about the history of the company, the technology
time line and the break through innovations till the todays state of the art equipment for R&D, prototyping and production. It will also come up with a couple of case
studies to underline the performance of the systems and technology.
76
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79
Friday, 6 Nov 2015 Bateleur

Medical
THE ROLE OF ADVANCED DIGITAL TECHNOLOGIES AND RAPID ADDITIVE
MANUFACTURE IN CRANIOFACIAL DISORDERS AND TRAUMA
D.G. Howes - Invited Speaker
University of the Witwatersrand; P-I Brnemark Institute, South Africa

dgh@branemarkinstitute.co.za
Abstract
Advanced Digital Technologies including surgical simulation and additive
manufacture has made significant advances possible in medicine and dentistry.
An investigation into oral health as part of the Global Burden of Disease (GBD)
2010 study showed that oral conditions affect as many as 3.9bn people worldwide
Craniofacial tumours and trauma are a daily occurrence and scourge in our society.
In addition 81,8% (+/- 51000) of the 60000 unnatural deaths in this country can be
attributed to interpersonal violence, road traffic accidents and suicide most of
which are directed at the head and neck!
The effective management of these diseases, injuries and tooth loss has been shown
to be effectively enhanced using modern scanning, simulation and rapid additive
manufacturing.
We have undertaken a number of studies using advanced software (Materialise;
Belgium) to help diagnose, simulate treatment and guide surgery in a variety of
craniofacial disorders, to the point where this technology is now indispensible in our
armamentarium. In addition, we have used advanced techniques to start measuring
treatment outcomes the next step in the validation of treatment protocols and
enhancing patient centred care.
This lecture will outline some of these digital pathways and report on the research
and treatment outcomes facilitated by advanced digital technology and rapid
additive manufacture.
80

Medical
ADVANCES IN MAXILLOFACIAL PROSTHODONTICS UTILISING AM
TECHNOLOGIES
GJ Booysen , C van den Heever - Invited Speaker

Central University of Technology, Free State (CUT)
gbooysen@cut.ac.za and cules@wol.co.za
Abstract
Very early in its development trajectory, the Centre for Rapid Prototyping and
Manufacturing (CRPM) was instrumental in developing surgery planning models to
support intervention surgery of a number of traumatic patient-specific cases. Being
part of Additive Manufacturing (AM) development in South Africa (SA), the CRPM
showcased the advantages this technology can offer to the medical fraternity. The
challenge was not only to supply the doctors with a digital model or design but to
actually manufacture the final implant to assist them in completing these extremely
difficult cases.
The paper will discuss successful developments in the field of patient-specific
prostheses which paved the way to develop a complete process chain from design
to manufacturing, with both time and cost savings as a further result. Materialise
design suite was used to design patient-specific mandibles, maxilla and
auricular prostheses. The EOS M280 Direct Metal Laser Sintering (DMLS) system was
instrumental in achieving the direct manufacturing of the bio-compatible titanium
implants. The EOS P385 system was used to manufacture the pre-operation planning
models as well as the positioning jigs and drill guides.
Case studies will focus mainly on patient-specific maxillofacial implants/prostheses, illustrating how these interventions improve the quality of life of SA patients.
Furthermore, the proposed paper and presentation will discuss the post-op reviews
of the patients showing the impact that AM has had on this sector.
81

Medical
EXPLORING THE USES OF ADDITIVE MANUFACTURING IN SOUTH AFRICA
K.B.F. White
Engineering Department, Southern Implants

kim.w@southernimplants.com
Abstract
Southern Implants is a biomedical-engineering company that designs and sells
dental implants. We work closely with some of the top dental specialists in the
country and often have to provide custom solutions for unique cases that these
doctors bring to us.
In this presentation we share how Additive Manufacturing (AM) was used for the first
time by us to solve one of these cases. We hope that it will inspire fellow industry
members to explore innovative AM solutions in their own industries.
The presentation is broken up into five main parts:

Background on our company and our specialized work

Overview of this particular patients case where AM was used

How we reached a point where we were able to choose AM and why we did

How we collaborated with others to produce a successful solution

Some of the lessons learnt from this project about AM in South Africa
The presentation concludes by encouraging industry peers to add AM to their own
toolboxes and explore application in their industries.
82

Medical
ADDITIVE MANUFACTURING IN THE EXPERIMENTAL DEVELOPMENT OF
PATIENT SPECIFIC INSTRUMENTATION AND PROSTHESIS FOR PATELLOFEMORAL KNEE REPLACEMENT
P.J. Erasmus, K.J. Cho, J.H. Mller

pieter@orthoclinic.co.za , kyjincho@gmail.com and cobusmul@sun.ac.za
Abstract
The shape and orientation of the patellofemoral joint is patient specific due to the
patients unique life style and genetic factors. The effect of patient specificity is that
off-the-shelf patellofemoral prostheses do not ensure a good fit in all patients. Patient
specific prosthesis and once-off instrumentation customize the fit and should improve
outcome of surgery. Four cadaveric knees were scanned with CT and the prototype
of patient specific patellofemoral arthroplasty systems were designed and fabricated
using additive manufacturing technology. The trial implants were implanted for each
of the four cadaveric knees in order to confirm the fit as well as the surgical procedures.
83

Medical
DEVELOPING A PROCESS FOR MANUFACTURING OF A POLYMER HEART VALVE
WB du Preez , L Masheane , J Combrinck, G Booysen

wdupreez@cut.ac.za, lmasheane@cut.ac.za, jcombrinck@cut.ac.za and
gbooysen@cut.ac.za
Abstract
Artificial heart valves have been developed over more than six decades and
represent the most widely used cardiovascular devices. Polyurethane valves have
performed the best in terms of resistance to thromboembolism and structural
deterioration, as well as biocompatibility. Progress made in developing a reliable,
affordable dip moulding process for repeatable production of tri-leaflet polymer
heart valves is reported. The initial valve design concepts are presented. Additive
manufacturing of Ti6Al4V (ELI) was used for producing the valve frame and the
mould. Preliminary production results from an experimental facility are presented
and evaluated with regard to compliance of properties such as leaflet thickness,
surface finish, mechanical strength and durability, with the requirements for heart
valves. Progress towards optimising the processing parameters is assessed and
discussed.
84

Medical
3D PRINTED THERMOPLASTIC POLYURETHANE FOR BIOMATERIAL
APPLICATIONS
D.A. Prawel, A. Beckwith, R. Simon-Walker, S.P. James, K.C. Popat

Department of Mechanical Engineering, School of Biomedical Engineering,
Colorado State University, Fort Collins CO 80524, USA
ketul.popat@colostate.edu
Abstract
Thermoplastic polyurethane (TPU) is an elastomer that is fully thermoplastic. Like
all thermoplastic elastomers, TPU is elastic and melt-processable. Further, it can
be processed on extrusion as well as injection, blow and compression molding
equipment. TPU is well suited for a wide variety of fabrication methodologies such
as 3D printing. In this study, NinjaFlex TPU material was extruded on a Lulzbot
3D printer into thin sheets of controlled thickness and texture, for the purpose of
evaluating the material for a variety of biomaterial applications. The biocompatibility of these 3D printed TPU sheets was evaluated with respect to possible
biomaterial applications. Human dermal fibroblasts were used for these studies. The
material toxicity was measured using LDH assay. Cell adhesion and proliferation was
characterized using fluorescence microscopy. Our results indicate that 3D printed
NinjaFlex material is non-toxic and is able to support cell adhesion and proliferation on the surface. Further studies are now directed towards evaluating mechanical
properties and cell-specific functionality on TPU surfaces.
NINJAFLEX is a trademark of J. H. Fenner & Co. Limited
85
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87
Friday, 6 Nov 2015 Cormorant

Materials, Processes & Simulation
ADVANCES IN PROCESS CONTROL AND QUALITY ASSURANCE IN
ADDITIVE MANUFACTURING
F.M. Sciammarella - Invited Speaker
Northern Illinois University, College of Engineering & Engineering Technology,

Mechanical Engineering Dept. DeKalb IL 60115 USA
sciammarella@niu.edu
Abstract
One of the major commercialization obstacles at this time for additive
manufacturing technology is the quantitative demonstration of repeatability and
reliability of the process across platforms. While the technology has been around
for several decades most advances have been done in an empirical fashion creating
point wise solutions. While statistical correlations exist for different Additive Manufacturing systems, there is no physics-based mechanistic understanding among the
fundamental process parameters, microstructure, and mechanical properties for
these different systems. This presentation provides an experimental and numerical
approach that attempts to address direct measurement of critical primary process
metrics that control microstructural and mechanical properties. Some of the accomplishments being made in this effort through the integration of a comprehensive
suite of in-situ experimental tools (i.e. calorimetry, laser ultrasound) have provided
insight into the Additive Manufacturing process and has enabled us to understand
the sensitivity of different process parameters. Eventually by coupling this with
predictive tools it will be possible to virtually develop precision process planning to
enhance component repeatability and reliability.
88

RESIDUAL STRESS IN Ti6Al4V OBJECTS PRODUCED BY DIRECT
METAL LASER SINTERING
I. van Zyl, I. Yadroitsava, I. Yadroitsev
Department of Mechanical and Mechatronic Engineering,

Central University of Technology, Free state, South Africa
ivanzyl@cut.ac.za, iyadroitsava@cut.ac.za, iyadroitsau@cut.ac.za
Abstract
Direct Metal Laser Sintering produces 3D objects using a layer-by-layer method in
which powder is deposited in thin layers. Laser beam scans over the powder fusing
powder particles as well as the previous layer. High-concentration of laser energy
input leads to high thermal gradients which induce residual stress within the as-built
parts. Ti6Al4V (ELI) samples have been manufactured by EOSINT M280 system as
prescribed by EOS process parameters.
Residual stresses were measured by XRD method. Microstructure, values and
directions of principal stresses in Ti6Al4V DMLS samples were analysed.
89

INFLUENCE OF PREHEATING AND OXYGEN CONTENT ON SELECTIVE LASER
MELTING OF Ti6Al4V
B. Vrancken, S. Buls, J.-P. Kruth, J. Van Humbeeck

University of Leuven, Belgium
bey.vrancken@mtm.kuleuven.be , sam.buls@kuleuven.be and
jean-pierre.kruth@kuleuven.be
Abstract
Selective Laser Melting of Ti6Al4V has already transitioned to commercial
exploitation, but is still coping with two major limitations that restrict a more
widespread use. Residual stresses can cause a premature build failure by inducing
cracks in bigger parts, and deformations of fine features during the build and of the
whole part after removal from the build platform. On the other hand, the ductility of
the martensitic microstructure is relatively low. Preheating of the build platform
may provide a solution for both problems. It reduces thermal gradients and thus
limits the development of residual stresses, but also causes a transformation of the
microstructure to a more ductile mixture of +. In this research, preheating of
the base plate up to 400C shows that residual stresses are reduced by 50%, and a
transformation of the microstructure to a ++ mixture. However, pickup of
interstitial elements at elevated temperatures during the process leads to an
embrittlement, reducing the ductility. Careful control of the atmospheric parameters
may eliminate this issue, paving the way for build platform pre-heating to solve the
current problems with SLM of Ti6Al4V.
90

MICROSTRUCTURAL AND THERMAL STABILITY OF SELECTIVE LASER MELTED
316L STAINLESS STEEL SINGLE TRACKS
P. Krakhmalev1, I. Yadroitsava2, G. Fredriksson1, I. Yadroitsev 2
Karlstad University, Sweden

Central University of Technology, South Africa
Pavel.Krakhmalev@kau.se, Gunnel.Fredriksson@kau.se , iyadroitsava@cut.ac.za and
iyadroitsau@cut.ac.za
1
2
Abstract
To remove residual stresses, an as-built SLM object is usually post treated. This
treatment can affect the microstructure, changing the final mechanical
characteristics. This investigation is focused on the microstructural characterization
of 316L austenitic stainless steel in as built and annealed conditions. The SLM microstructure was relatively stable up to 900C, when cell boundaries start to disappear.
At higher temperatures an insignificant grain coarsening was detected. These microstructural changes caused a gradual drop in the hardness. The obtained result is a
background for the future development of post treatment regimes to achieve a high
level in the final mechanical properties of SLM objects.
91

THERMO-MECHANICAL FINITE ELEMENT ANALYSIS OF
MULTILAYER LASER METAL DEPOSITION
S. Kumar 1, M. Shukla 1,2 A. Das1
MNNIT, Allahabad, India

University of Johannesburg, Johannesburg, South Africa
skspassion@gmail.com, ashishdas.1110@gmail.com, mshukla@uj.ac.za and
mukulshukla@mnnit.ac.in
1
2
Abstract
In this paper the thermal history including melt pool size and thermo-mechanical
residual stress distribution in multilayer laser metal deposition of stainless steel
410 (SS410) on SS410 substrate was investigated numerically using Finite Element
Analysis (FEA). The commercial FEA software COMSOL Multiphysics 5.0 was used to
develop a three-dimensional thermo-mechanical FE model, considering the effect
of temperature dependent thermo-physical properties. The obtained results were
found to be in close agreement with the published literature.
92

INKJET-PRINTED CONDUCTIVE FEATURES FOR RAPID INTEGRATION OF
ELECTRONIC CIRCUITS IN CENTRIFUGAL MICROFLUIDICS
J. Kruger 1, S. Smith 2, K. Land 2, M. du Plessis 1, T-H. Joubert 1
University of Pretoria, South Africa

Council of Scientific and Industrial Research, South Africa
u10066081@tuks.co.za , ssmith@csir.co.za , kland@csir.co.za, monuko@up.co.za and
trudi.joubert@up.co.za
1
2
Abstract
This work investigates the properties of conductive circuits inkjet-printed onto
the polycarbonate discs used in CD-based centrifugal microfluidics, contributing
towards rapidly prototyped electronic systems in smart ubiquitous biosensors,
which require sensitive and robust signal readout at low power and cost, and with
wireless connectivity. A protocol for inkjet-printing electronic networks on CD
substrates is developed. The circuit modeling of conductive tracks is discussed, and
validated against experimental results. A design procedure is presented for reliably
printing conductive networks with feature dimensions between 150 m and 2 mm
on CDs, and yielding electronic circuits operating with a bandwidth of 1 MHz.
93

PLUG-AND-PLAY PAPER-BASED TOOLKIT FOR RAPID PROTOTYPING OF
MICROFLUIDICS AND ELECTRONICS TOWARDS POINT-OF-CARE
DIAGNOSTIC SOLUTIONS
S. Smith, K. Moodley, K.J. Land
Department of Materials Science and Manufacturing

Council for Scientific and Industrial Research, South Africa
ssmith@csir.co.za, kmoodley2@csir.co.za and kland@csir.co.za
Abstract
We present a plug-and-play toolkit for the rapid assembly of paper-based
microfluidic and electronic components for quick prototyping of paper-based
components towards point-of-care diagnostic solutions. Individual modules, each
with a specific function, have been developed to connect together in different
sequences and combinations, allowing for a variety of microfluidic and electronic
functions to be implemented and integrated in a rapid, interchangeable and reusable fashion. This toolkit provides educational blocks for understanding both
paper-based microfluidic and electronic components and the capabilities to develop
paper-based systems rapidly and at a low cost using both hand-made and printable
techniques.
94

Materials, Process & Simulation
A COMPARISON OF DIFFERENT SILVER INKS FOR PRINTING OF CONDUCTIVE
TRACKS ON PAPER SUBSTRATES FOR RAPID PROTOTYPING OF ELECTRONIC
CIRCUITS
P.H. Bezuidenhout 1, S. Smith 2, M. Mbanjwa 1, K.J. Land 1,

T-H Joubert 1
Materials Science and Manufacturing, CSIR, Pretoria

Department of Electrical, Electronic and Computer Engineering, University of
Pretoria, Pretoria
pbezuidenhout@csir.co.za, ssmith@csir.co.za, mmbanjwa@csir.co.za,
kland@csir.co.za and trudi.joubert@up.ac.za
1
2
Abstract
This study compares the performance between two commercially-available
electrically conductive silver inks, Harima NPS-J nanopaste and the NBSIJ-FD02
Mitsubishi conductive ink, used in rapid prototyping of electronic circuits. The
comparative parameters include resistivity relative to bulk silver, conductivity,
geometric properties achievable relative to design parameters and frequency
characteristics. These parameters are useful in the development of electronics on paper,
and provide a clearer understanding of the selection process of different conductive
inks for printing onto paper substrates. These results can be utilized in the development
process for fully printable rapidly prototyped electronic systems, which can range from
environmental sensing solutions, to wearable devices and low-cost medical diagnostics.
95

DIRECT METAL LASER SINTERING, UTILISING CONFORMAL COOLING, FOR
HIGH VOLUME PRODUCTION TOOLING
B. van As 1, J. Combrinck 2, G.J. Booysen 2, D.J. de Beer 3

3
North West University, South Africa
bertusvanas@gmail.com, jcombrinck@cut.ac.za, gbooysen@cut.ac.za and
deon.debeer@nwu.ac.za
1
2
Abstract
Existing techniques for the production of conventional steel tooling for plastic
injection moulding are prohibitively expensive and time consuming. In addition,
complex geometries are not always possible to manufacture using conventional
techniques. Complex mould inserts that cannot be manufactured by traditional
processes can be produced in parallel to conventional tooling methods within
a very short lead-time. This can be achieved by using Direct Metal Laser Sintering (DMLS) of Maraging tool steel. Maraging Steel (MS1) is an Additive Manufacturing (AM) material made available recently by EOS. This pre-alloyed ultra-high
strength steel is supplied in fine powder form. It has very good mechanical properties, and is easily heat-treatable using a simple thermal age-hardening process to
obtain excellent hardness and strength. Contrary to material removal processes,
DMLS of MS1 can produce tool steel parts directly from computer aided design
(CAD) that is suitable for high volume plastic injection moulding. Through DMLS
it is possible to create conformal cooling channels in injection moulding inserts
that have advantages in reducing heat, rapidly and evenly. This can significantly
reduce cycle time (there-by reducing the cost of product) and increase moulded part
quality by eliminating defects such as warpage and heat sinks in plastic products.
The paper will present a comparison of finite element analysis (FEA) simulations of
the mould inserts using Sigma Flow with actual mould trails. It includes the design
and manufacture of conventional and DMLS inserts and compares the cost and lead
time of insert manufacturing. Using FEA simulations, conformal cooling channel
design is optimised by comparing the internal mould temperature of different
cooling channel geometries.
96

EFFECTIVENESS OF ACETONE POST-PRODUCTION FINISHING ON
ENTRY LEVEL FDM PRINTED ABS ARTEFACTS
S.P. Havenga 1, D.J. De Beer 2, P.J.M Van Tonder 1, R.I. Campbell 1

North West University, South Africa
mercurion222@gmail.com, deon.debeer@nwu.ac.za, sarelh@vut.ac.za,
malanvt@vut.ac.za and r.i.campbell@lboro.ac.uk
1
2
Abstract
In the quest to improve post-production finishing techniques on entry level Fused
Deposition Modelling printed artefacts, two main areas persistently stand out
as limitations, namely the structural integrity of assembled artefacts after postproduction treatment and the surface finish quality. After an extensive preexperimental case study, acetone (propan-2-one/ dimethyl ketone) was identified as
one of the most promising post-production finishing materials. This paper describe the
effects that acetone post-production finishing has on the structural integrity and surface
finishing of an entry level Fused Deposition Modelling Acrylonitrile Butadiene
Styrene printed artefact.
97
Notes
98
Notes
99
Friday, 6 Nov 2015 Barn Owl

Industry Case Studies
LASER-BASED REFURBISHMENT IN THE POWER GENERATION INDUSTRY
H. Burger - Invited Speaker
National Laser Centre, CSIR, Pretoria, South Africa

hburger@csir.co.za
Abstract
Steam turbine rotors are subjected to high stresses during operation. High stresses occur in the rotor shaft journal and blade root areas. Weld repair in these areas
have successfully been performed by various original equipment manufacturers.
Successful repair of turbine and compressor rotors require exceptional weld quality,
excellent process control and high repeatability.
The National Laser Centre at the Council for Scientific and Industrial Research has
developed laser metal deposition process parameters for the refurbishment of steam
turbine and compressor components. Together with MAN Diesel and Turbo and
Eskom, various rotors have been repaired by the CSIR mobile laser metal deposition
system with great success. Laser metal deposition repairs included journal areas,
mechanical seal areas, thrust collar, internal diameter weld build up, hydrogen seals
and split faces as well as grey cast iron blade carriers.
Laser metal deposition offer distinct advantages compared to arc welding processes
which include low heat input, low dilution, reduced distortion, improved mechanical
and impact properties of the weld overlay and near net-shape build up.
100

A BRIEF OVERVIEW AS TO THE USE OF AM WITH FOCUS ON WHERE EXPECTATIONS HAVE BEEN EITHER DISAPPOINTING OR EXCEEDED
J. Malan
John Malan Design cc, South Africa

john@merindol.com
Abstract
I have been practising for over 34 years as a one man design consultancy specializing
in new product development spanning toys to aerospace and collaborations with
my wife on bespoke fine jewellery.
My design work leans towards systems and assembly related projects as opposed
to single isolated item design and so inter-part function, fit and tolerance is a big
consideration for me.
My philosophy is to try to apply development tools that are relevant to requirement,
applied at a time when these add value to the product development process. My
belief is that a 3D print is only as good as the originating digital 3D model and how
well this suits the print process to be selected. In my case the CAD model for 3d
printing quite often differs from the actual production design. The printed model
needs to be fit for purpose; is it for marketing or a functional model for testing, a tool
or jig or even an end product in itself?
To this end I have used a variety of processes offered by the CRPM, VUT, the NLC and
others in the course of developing consumer, commercial and industrial products.
My first direct experience of 3D printing was 3D Systems Laser stereo lithography in
the mid 1990s (Bob Bond / CSIR). I bought and still use a Stratasys Dimension BST
(ABS FDM) printer in March 2004 for my business and personal use.
101

HOW 3D PRINTING IS CHANGING THE WORLD OF JEWELLERY
J. Laing
J-Lee Inc., South Africa

jason@hybrid3d.co.za
Abstract
Having worked as a traditional gold smith for almost 20 years I have seen the
changes and difficulties that have come about through the production process of
the jewellery industry.
Over the years having worked locally and international in the jewellery field
jewellery has become one of the fasted growing areas in order to be able to compete
as a jeweller internationally and to the level that the commercial market is requiring
without the huge costs required in set up of a factory as tradionally established. In
my lecture I will discuss how 3D printing has managed to overcome major traditional
production obstacles for all jewellers ranging from the home jeweller to the mass
production entities. I will cover how 3D printing has in contrary to belief is actually
creating jobs in the industry and not creating unemployment as previously though
would happen.
I will present some samples of this process and how even the home user through
simple training has now been able to become self-employed within the jewellery
industry
102

ADDITIVE MANUFACTURING AS A TOOL IN CONSUMER ELECTRONICS
DEVELOPMENT
Dylan Hemer
Altech Multimedia, South Africa

dylan.hemer@altech-multimedia.com
Abstract
Altech Multimedia is a consumer electronics company located in Durban with a
core business developing Set Top Boxes (STBs). Altech Multimedia has been using
Additive Manufacturing (AM) for a number of years for R&D prototypes (engineering fitment and development testing) and aesthetic samples used for sales and
marketing purposes. Feedback is given on various plastic AM technologies employed
by the company and the suitability of each is discussed. A case study is presented on
how AM allowed very tight deadlines to be met which otherwise would not have
been achievable. With the recent purchase of an FDM machine Altech Multimedia
now has in-house AM capability and difficulties and successes relating to this are
presented.
103

ROLE OF RAPID PROTOTYPING DURING AIRBORNE PRODUCT DEVELOPMENT
G. Smit
Airbus DS Optronics, Irene South Africa

gerhard.smit@airbusds-optronics.com
Abstract
Traditional development cycles for the development of new elements of airborne
observation systems typically required two to three years. Due to the increasing rate
at which improved technology come onto the market, end user expectations have
also risen to see these improvements in final products in months rather than years.
By making use of powerful development tools such as computer aided design and
simulation the development process can be shortened but some aspects of development cannot be accurately simulated. Additive manufacturing make it possible to
rapidly create functional components that can be used for: validation of simulation,
fitment and assembly checks, ergonomic evaluation, production improvements and
even final components used in the finished product. These and other aspects are
discussed during a typical product development cycle of airborne products at
AIRBUS DS OPTRONICS.
104

GROWING CENTURION SYSTEMS THROUGH ADDITIVE MANUFACTURING
A. Viljoen
CENTSYS, South Africa

alwyn.viljoen@centurionsystems.co.za
Abstract
Centurion Systems is in the business of mass producing access automation
equipment. Continuous growth of the product basket is required to continue the
exceptional growth the company has seen over the past three decades. One of
the drivers behind investing in Additive Manufacturing tools was to attempt to
realise more radical innovation in the business. Without the tools, our mechanical
engineering was often far more conservative because we couldnt physically test
complex part interactions and we couldnt rapidly iterate through many conceptual
ideas.
Various types of Additive Manufacturing techniques have been used in many
different applications, the examples that will be presented include:
1.The relatively affordable CubeX with PLA was used to manufacture jigging to hold
semi finished assemblies on the Production Line. The cost and time savings meant
the capital investment in the CubeX was paid off within the first set of jigs that was
produced.
2. The more advanced Objet30 Pro machine was used with VeroWhite for conceptual
product reviews. By using sanding paper and spray paint, designers are able to produce very representative physical models for stakeholders to hold and feel.
3. Negative moulds were printed with the Objet 30Pro in VeroClear. Black silicone
was injected into the moulds to produce a prototype silicone seal profile for one of
the linear operators. The quick turnaround time between concepts allowed for many
iterations in a short time to get to an optimized solution.
105

MAKING KNOWN THE UNKNOWN
Henk van der Meijden

Henk and I cc, South Africa
handi@icon.co.za
Abstract
A unique story behind a unique product. Be inspired as Henk shares the joys and
pains of the birth of a new business through the development of a world first. Now
ready to launch after 3 years of intensive development with the aid of FDM, he shares
the critical development path of this unique product range from inception, through
testing and refinement, to tooling. Due to hit stores in South Africa in January, this
is the first time this development is publically disclosed. Be part of the process of
making the unknown known.....
106

Industry case studies
THE INTRODUCTION OF RAPID PROTOTYPING TO THE JEWELLERY
MANUFACTURING INDUSTRY
C. van Rensburg
Jewellery Council of South Africa

chris@studioc.co.za
Abstract
In 2002 I was the first manufacturing jeweller to use rapid prototyping ie; Solidscape
3D Printing. Soon after I became the agent for the brand, which at the time with its
high resolution and castability was ideal for the jewellery Industry. Over a four year
period I sold 38 Solidscape Printers into the Jewellery Manufacturing Industry. The
biggest challenge soon became apparent. The lack of CAD designers! Historically
the same as Tool & Die makers and other engineering manufacturing plants, there
were always the journeyman, the artisan and the apprentice. Rapid Prototyping
turned all this on its head. The challenge was not to teach entrants into the industry
how to use this new tool CAD, but what to do with the new tool. Its a Catch 22. You
need jewellery manufacturing experience to be able to use this new tool and most of
the experienced artisans were also techno phoebes who had no idea how to switch
on a PC. Then the issue of staff poaching began (The most skilled / semi-experienced
CAD designers). With this, demand for skilled artisans declined but created lower
skilled employment opportunities. This was frowned upon by government as all the
structures set up for training and education mostly supported high end skills. The
most important evolution brought about by Rapid Prototyping is that we have become more competitive in global jewellery manufacturing terms.
107

Industry case studies
THE SADDLE TREE FROM WOOD TO NYLON
B. Liebenberg
Franco C Saddlery, South Africa

ben@franco-c.com
Abstract
Saddle trees were traditionally made from wood, and they still are in many parts
of the world. These wooden saddle trees are often covered with rawhide, fiberglass
or fabric. Fiber glass and plastics are lighter and cheaper and becoming the norm
but the original designing is generally still done by hand. The end result is seldom
100% symmetrical and true. The use of 3d technology has revolutionized the way we
at Franco C Saddlery design and produce saddles over the past 7 years. As a result
we can produce saddle trees that are 100% symmetrical and fine-tuned to customer
needs. With nylon 3D printers we are now able to produce a ridable prototypes, bespoke saddles and designs that were impossible with traditional methods.
108
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109
Notes
110
Notes
111
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112

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Additive Manufacturing

ideas into business

4 - 6 November 2015, Roodevallei, Pretoria, South Africa

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Gain exposure to the latest developments in the field of AM;

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

General Information - Technical Committee

Mrs. Maritha Theron

Mr. John Barnes

Dr. Richard Grylls

Prof. Michle Truscott

Dr. Thorsten Becker

Prof. Jorrie Jordaan

Dr. Dawie van den

Mr. Jeff Benson

Dr. Kobus Van der Walt

Prof. Uwe Berger

Mr. Herman Rossouw

Prof. Milan Brandt

Dr. Igor Yadroitsau

Mr. Herman Burger

Dr. George Vicatos

Mr. Charl Smal

Prof. Olaf Diegel

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

General Information - Organising Committee

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Program Manager and Director Aerosud Innovation

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Project Manager: Additive Manufacturing

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

President, Wohlers Associates, Inc

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Vice President & Manager Emerging Technologies &

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Member of the Board of Directors

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Monash University, Melbourne, Australia

SELECTIVE LASER MELTING (SLM) OF AEROSPACE MATERIALS, ITS QUALITY

R. Chu, N. Perevoshchikova, J Mei, T. Jarvis, P Rometsch, D Tomus, R. Boyer and

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Senior Mechanical Engineer, GE Global Research Centre,

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Associate Professor at UCT, Mechanical Engineering

TITANIUM DEPOSITION BY AM/SLS PROCESS ON THE SURFACE OF AN ANNEALED

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Loughborough University, Loughborough, UK

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Tuesday, 3 November 2015

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Wednesday, 4 November 2015

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Wednesday, 4 November 2015

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business

Thursday, 5 November 2015

RAPDASA 2015 l Additive Manufacturing - Transforming ideas into business