Rapid Prototyping Technology in South Africa

Transcription

1 Rapid Prototyping Technology in South Africa Dr Willie du Preez Manager: Metals & Metals Processes CSIR Institute of Inventors and Innovators 13 April 2011 RAPDASA 2011 Slide 1

2 Overview What is Rapid Prototyping? The History of Rapid Prototyping in South Africa Launch of RAPDASA National Product Development Centre (NPDC) Centre for Rapid Prototyping and Manufacturing (CRPM) and Technology Stations Industry Response Rapid Prototyping applications The Future? RAPDASA 2011 Slide 2

3 What is Rapid Prototyping? RAPDASA 2011 Slide 3

4 Prototyping Definition: an approximation of the product along one or more dimensions of interest Any entity exhibiting at least one aspect of the product that is of interest can be viewed as a prototype Physical vs analytical prototypes Comprehensive vs focused prototypes RAPDASA 2011 Slide 4

5 Rapid Prototyping (RP) The transformation of a concept in CAD format into a physical 3D object in the shortest possible time without human intervention during the transformation process - It results in an exact point-to-point physical representation of a 3D model on a computer - All RP technologies are based on building 3D objects by stacking 2D layers on each other - This enables you to reproduce any external and/or internal geometry RAPDASA 2011 Slide 5

6 Rapid Prototyping Technologies RP Technologies available in South Africa: Stereolithography: CUT Fused Deposition Modelling: NMMU Selective Laser Sintering: CUT Polymers Sand Steel Titanium alloy (Ti-6Al-4V) Other materials Laminated Object Manufacturing: CPUT 3D Printing Modelmaker (Sanders): CUT Z-Corp: SU 3D Systems: NMMU, others RAPDASA 2011 Slide 6

7 Selective Laser Sintering (SLS) CSIR

8 The History of Rapid Prototyping in South Africa RAPDASA 2011 Slide 8

9 GARPA Global Summit 98 RAPDASA 2011 Slide 9

10 Launch of RAPDASA Launch meeting hosted by Prof Dimitri Dimitrov in Stellenbosch at the end of 1999 Decision on the scope of RAPDASA: Rapid Product Development rather than only Rapid Prototyping To promote collaboration and concurrent engineering among individuals and enterprises involved in product development, nationally, as well as internationally 1 st Conference and AGM on 7 & 8 November 2000 at the CSIR in Pretoria RAPDASA 2011 Slide 10

11 The National Product Development Centre

12 Product Development Collaborators Associations: RAPDASA GARPA PU TFS-CRPM Technology Station UNIN Materials Modelling Centre NPDC Hub CSIR UP Tri-CAD (Pty) Ltd AIDC (Pty) Ltd Wits SABS Pretoria Technikon Technikon Northern Gauteng Technikon Witwatersrand NAMAC SASOL Polymers Durban Institute of Technology UND UDW DUMAC M&M Coastal EC Technikon US-GCC CERECAM Pentech M&M Coastal CapeTechnikon PE Technikon Auto Components Technology Station PERMAC CSIR-CFTC RAPDASA 2011 Slide 12

13 Product Development Technologies & Methodologies Design Research Industrial Design Reverse Engineering Digitising Surfacing DFMA Quality Function Deployment Data Exchange CAD Solid/Surface Modelling Materials Selection CAM Tool Paths CNC Machining Rapid Tooling Soft Tooling Bridge Tooling Hard Tooling FEM Structural, Thermal & Dynamic Optimisation Durability Process Simulation Casting Metal Forming/Forging Injection Moulding Tool Design CAD Tool Manufacture CAM Production Rapid Prototyping Stereolithography Fused Deposition Modelling 3D Printing Selective Laser Sintering Z-Corp 3D Modeller Laminated Object Manufacturing Direct Prototyping Investment Casting RAPDASA 2011 Slide 13

14 Centre for Rapid Prototyping & Manufacturing (CRPM) and Technology Stations RAPDASA 2011 Slide 14

15 3D Systems 1991 / CSIR in 1994 Start of my own involvement in

16 CRPM and Technology Stations (Tshumisano) Establishment of the Centre for Rapid Prototyping and Manufacturing (CRPM) at the Technikon Free State (now CUT) by Prof Deon de Beer DST launched their Technology Stations Programme Product Development Technology Station (PDTS) the flagship at CUT Automotive Components Technology Station (ACTS) at NMMU RAPDASA 2011 Slide 16

17 CRPM today.

18 South African Industry Response RAPDASA 2011 Slide 18

19 Rapid Product Development and RP in Aerosud Paul Potgieter (Jnr): Benefits of Rapid Prototyping in Wind Tunnel Testing Wouter Gerber: Applied Fundamentals of Design for Manufacture (DFM) in the Digital Environment Andries Uys: Alumide Tooling in the Forming Process Marius Vermeulen: Chairperson of RAPDASA RAPDASA 2011 Slide 19

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21 Aerospace Press Tools

22 Engine Development

23 RP Landscape in 2010 SA AF Landscape Total Machines 3DP RAPDASA 2011 Slide 23

24 RP Applications RAPDASA 2011 Slide 24

25 Isuzu tail-light development

26 AMAP Kettle

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30 Medical Product Development DMLS of Titanium Prototypes

31 Titanium Laser Sintered Prototypes/Parts Jaw implant for Prof Dale Howes (JHB) Lattice structures (UCT) to encourage bone re-growth

32 Titanium Laser Sintered Prototypes/Parts Knee implants for US (PhD project) Parts for Russia axial blood pump

33 Spinal parts for US (PhD project) Directly manufactured in TI64 titanium

34 The Future? RAPDASA 2011 Slide 34

35 Towards Future Factories? AM Platforms in itself are small factories especially in terms of reconfigurability!

36 Alternative materials products or tools

37 Alternative materials final products

38 Alternative materials final products, jigs & fixtures

39 Future.. Additive Micro-manufacturing?

40 Future.. Additive Micro-manufacturing?

41 The Future Undoubtedly there will be an increased number of machines/technologies. Additive manufacturing OEMs probably should focus more on machine development for AM producing large structures In parallel, local material development should start to bring costs down.

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44 Thank you! RAPDASA 2011 Slide 44