1. HIGH SPEED, LARGE VOLUME ADDITIVE MANUFACTURING
MARIUS VERMEULEN
ADC AEROSWIFT

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

3. ADC Facilities Aeroswift facilities (350 m2) ADC facilities (7830 m2)
CSIR, Pretoria
Aeroswift Research & Development teams
Aeroswift machine location
ADC facilities (7830 m2)
Wonderboom Airport, Pretoria
AHRLAC manufacturing and
Aeroswift production teams

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

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

6. Metal additive manufacturing applications in South Africa

7. Customised Titanium mandible implant

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

9. Additively Manufactured heart valve assembly
DMLS
Dip moulding

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

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

12. 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
4.5X size of largest commercial machine, ~40x standard
commercial machine
 Part sizes up to 2 m in present configuration
 Simultaneous manufacturing of various parts (batch processing, reducing part cost)

13. 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-6Al-4V
Stainless Steel alloys
Inconel
Aluminium
Other metals

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

15. Aeroswift in the AM technology landscape
HIGHE
VALUE
Powder bed
systems
Aer
oswift
Part complexity
Powder Deposition systems
Wire deposition systems
<500mm
>2000mm
Part size

16. 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

17. Thank You