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High-Speed, Large Volume Additive Manufacturing - Aerospace Development Corporation (ADC)

ADC Aeroswift specializes in the design, manufacture, and supply of products for the commercial aviation industry, including high-speed, large volume additive manufacturing. They also offer non-destructive testing for the aviation industry. Visit www.aerosud.co.za for more information.

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High-Speed, Large Volume Additive Manufacturing - Aerospace Development Corporation (ADC)

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  1. HIGH SPEED, LARGE VOLUME ADDITIVE MANUFACTURING MARIUSVERMEULEN ADCAEROSWIFT

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

  3. ADCFacilities Aeroswift facilities (350m2) CSIR,Pretoria Aeroswift Research & Developmentteams Aeroswift machinelocation ADC facilities (7830m2) Wonderboom Airport,Pretoria AHRLAC manufacturingand Aeroswift productionteams

  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. Metal additive manufacturing applications in South Africa

  6. Customised Titanium mandible implant

  7. Customised Titanium mandible implant • At the CRPM inBloemfontein: • More than 70 patients assisted with 3Dprinted • medical devices, implants and externalprostheses • ~55 of these received titaniumimplants • ISO 13485certification

  8. Additively Manufactured heart valve assembly DMLS Dipmoulding

  9. AM Refurbishmentexamples • Blade tenonrebuild • Leading edge erosionrepair • Turbine journalrepair

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

  11. Aeroswift valueproposition • 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)

  12. Aeroswift valueproposition • 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

  13. The advantage ofspeed Unit costs forconventional manufacturing Unit cost($/part) AMAM ConvCeonntivoennatlional Unit costs for AM is constant, irrespective of manufacturing volume Breakeven Manufacturing volume(parts/year)

  14. Aeroswift intheAM technology landscape R HIGHE VALUE Powder bed systems Aer oswift Partcomplexity Powder Deposition systems Wire deposition systems <500mm >2000mm Partsize

  15. 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

  16. ThankYou

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