HIGH SPEED LARGE VOLUME ADDITIVE MANUFACTURING MARIUS VERMEULEN

HIGH SPEED, LARGE VOLUME ADDITIVE MANUFACTURING MARIUS VERMEULEN ADC AEROSWIFT

Company family Aerospace Development Corporation (Pty) Ltd (ADC) Design, manufacture and supply of products for the commercial aviation industry www. aerosud. co. za Africa NDT Centre(Pty) Ltd AHRLAC (Pty) Ltd Aerosud Innovation Centre(Pty) Ltd Non-destructive testing for aviation industry South African developed and produced Aircraft. www. ahrlac. com Product and process development in the field of Aerospace (including High speed Additive Manufacturing) ADC Aeroswift (Pty) Ltd High-speed, large volume Additive Manufacturing

ADC Facilities ADC facilities (7830 m 2) Wonderboom Airport, Pretoria Aeroswift facilities (350 m 2) CSIR, Pretoria AHRLAC manufacturing and Aeroswift production teams Aeroswift Research & Development teams Aeroswift machine location

Additive manufacturing (AM) is defined by ASTM as the "process of joining materials to make objects from 3 D model data, usually layer upon layer, as opposed to subtractive manufacturing methodologies. ”

Additive Manufacturing Traditional Manufacturing Low volume, high value parts Often cheaper Design Freedom (complex parts) Part consolidation; Weight reduction Mass Production Reduced Wastage Exotic materials Reduced need for tooling Speed to Market Reduced / simplified supply chains Choice of Materials Large Parts Known technology

Metal additive manufacturing applications in South Africa

Customised Titanium mandible implant

Customised Titanium mandible implant At the CRPM in Bloemfontein: • More than 70 patients assisted with 3 D printed medical devices, implants and external prostheses • ~55 of these received titanium implants • ISO 13485 certification

Additively Manufactured heart valve assembly DMLS Dip moulding

AM Refurbishment examples o Blade tenon rebuild o Leading edge erosion repair o Turbine journal repair

Titanium in South Africa Billet Ingot Sponge Extensive Machining 90+% Waste Ore Powder South African Development <5% Min Machining Final Part South African Additive Aero. Swift Capability Manufacturing

Aeroswift value proposition • High processing speed by using high power laser technology – 5 to 10 times faster than present best in class commercial systems Reduction on part production cost • Large processing platform – 4. 5 X size of largest commercial machine, ~40 x standard commercial machine Part sizes up to 2 m in present configuration Simultaneous manufacturing of various parts (batch processing, reducing part cost)

Aeroswift value proposition • Linear scanning approach – Customised processing bed to fit specific part geometries – Efficient localised vapour extraction Improves integrity in large-bed processing – Single laser source Reduce risk and simplifies part qualification in highly regulated industries • Pre-heating technology – In process heat treatment to reduce residual stress in components, critical for larger components • Materials – – – Ti-6 Al-4 V Stainless Steel alloys Inconel Aluminium Other metals

The advantage of speed Unit cost ($/part) Unit costs for conventional manufacturing AM AM Conv. Ceonntivoen natlional Breakeven Manufacturing volume (parts/year) Unit costs for AM is constant, irrespective of manufacturing volume

Aeroswift in the AM technology landscape Part complexity Powder bed systems HIGHER VALUE Aeroswift Powder Deposition systems Wire deposition systems <500 mm >2000 mm Part size

Status • First flying parts - 14 July 2017 • Programs ongoing with a range of South African and international customers • First industrial Aeroswift machines in production - end 2019

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