The CSIR and its industry partners - the Department of Science and Technology (DST), National Research Foundation (NRF), Aerospace Industry Support Initiative (AISI) and Aerosud - will launch a multimillion-rand Additive Manufacturing platform.

This dual launch will take place at the CSIR National Laser Centre and at Aerosud Innovation and Training centre (Phase II) (ITC-2) located at Centurion Aerospace Village (CAV).

The launch – to be attended by DST’s Deputy Minister, Derek Hanekom, and other industry VIPs – is scheduled for Friday, 27 January at the CSIR.

CSIR’s multimillion additive manufacturing platform a boost for industry

The CSIR in collaboration with Aerosud tabled a funding proposal to the DST to support the development of a high speed large area additive manufacturing (HSLA-AM) technology platform.

The DST approved the funding proposal and allocated R28 million to the CSIR and as part of this, the CSIR had to invest in a specialised laser source to the value of R10 million. The laser, which is part of the HSLA-AM system, has now arrived.

CSIR’s Prof Federico Sciammarella, says: “This system will be the first of its kind in the world as it will be able to build parts with an envelope of 2 x ½ metres; this is critical when making components for the aerospace industry that require precision and high quality.”

He adds: “This system will place South Africa on the forefront of additive manufacturing technology and enable the aerospace industry to produce parts for the global community.”

In addition to this, CSIR also secured grants from NRF and the dti’s AISI to invest in a research and development (R&D) facility to focus on powder blown Laser Metals Deposition additive manufacturing technology, or the Laser Engineered Net Shaping (LENS) technology. This piece of R&D equipment was procured from suppliers in United States and is being installed at NLC’s laboratories.

The launch will culminate in the unveiling of the LENS. The LENS technology offers the opportunity to create 3-D parts without the need of any specialised tooling. It also has the capability to refurbish components.

Refurbishment of industrial components is particularly important in the South African context. South Africa’s manufacturing industry relies on imported equipment and critical spares have to be kept in stock or be imported from overseas. Where high value parts are involved, manufacturing companies have to choose between expensive spare part inventories or the possible loss of production due to downtime while spare parts are being imported. The LENS offers the ability for companies to avoid those scenarios buy rebuilding their existing parts.

The Additive Manufacturing technology platform established at CSIR National Laser Centre is geared to support the strong partnerships that have been established by the Centre and its industry partners, specifically Aerosud. Through the technology platform, it is envisaged that South Africa will accelerate the beneficiation of local resources such as Titanium, which is of critical importance for the Aerospace industry.

AEROSUD MANUFACTURING PROCESS DEVELOPMENT GROUP MOVES IN AT THE CENTURION AEROSPACE VILLAGE (CAV).

The Aerosud Process Development group has moved in at the heart of the Centurion Aerospace Village (CAV) in the Innovation & Training Centre II (ITC-2). Process Development focuses on improving the manufacturing capability of the South African aerospace industry. The Department of Trade and Industry (the dti) and Department of Science and Technology (DST), through Technology and Innovation Agency (TIA) and CSIR has partnered with Aerosud and other industry players in the development and commercialisation of manufacturing technologies that would globally position the South African aviation industry to become more competitive in high-end manufacturing technologies. The ITC-2 will also function as a technology incubator and support facility to the larger CAV community.

Aerosud Process Development consists of the following research groups:

Additive Manufacture: Manufacture of highly complex aircraft parts via laser melting of exotic metal powders such as Titanium and Cobalt-Chrome.

Advanced Composites: Rapid press-forming of continuous fiber reinforced thermoplastics (CFRTP) and rapid curing pre-pregs, vacuum infusion, adhesive bonding, and rubber technology. 

Advanced Metrology: Employs the latest in coordinate measuring machines (CMM) coupled with laser scanning technology to optimize quality assurance and digital design cycles.

Automation: Machine automation and development of control & data-acquisition systems.

Digital Manufacture: refers to high tolerance machining with a fully digital design and configuration cycle. This ensures maximized efficiency on the machines and total repeatability.

Metal Technology:  Forming, joining and mechanical/ thermal/ chemical processing of Aluminium and Titanium alloys for aerospace applications.

The synergy of the abovementioned groups enables Process Development to deliver turn-key manufacturing solutions to any customer specification including design of parts & tooling, material selection, equipment & process development, qualification & industrialization and staff training.

Process development cooperates nationally and internationally with government, industry and tertiary education on both Technology and Human Capital Development (HCD) projects. Projects are aligned at an early stage with the short or long-term requirements of future customers in order to reduce the time to market and to make sure that the right technology is developed and the right people are trained at the right time.

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