No description available.

Thesis (MScIng)--University of Stellenbosch, 2005. / Bibliography. Also available via the Internet.

Published Article / Over the past few years, methods of layered manufacturing (LM) have advanced substantially to the point where they now provide vital strategic benefits to various organisations. One area of application where LM technologies have begun to reach a critical mass is in the development and production of high-performance tooling in different forming processes. With these tooling capabilities now available, the next challenge becomes the development of optimal process chains to minimise lead times and production costs, while still ensuring high quality of castings. The relevant issues that influence where a break-even point will be between different process chains and thereby also the point of selection between such optimal process chains according to different situations include among others: <ul> <li> the size of production runs, </li> <li> part size and complexity, and</li> <li> the cast materials involved.</li> </ul> <br>This paper reflects some of the experiences gained from an investigation towards developing a set of generic rules (guidelines) for the design of optimal process chains for sand casting prototypes of automotive components using LM methods, and more specifically the 3D Printing process.

Thesis (MScIng)--University of Stellenbosch, 2008. / Bibliography. Also available via the Internet.

Thesis (MTech (Mechanical Engineering))--Cape Peninsula University of Technology, 2010. / The research presented in this report focuses on Investment Casting capabilities for light metal alloys in South Africa and forms part of the Advanced Manufacturing Technology Strategy's (AMTS): Light Weight Metals flagship programme. The research is centred on the suitability of rapid prototyping (RP)/Iayer manufacturing (LM) methods to produce patterns for the investment casting of aluminium (AI), magnesium (Mg) and titanium (Ti) alloys, together known as Rapid Investment Casting. Three core RP technologies are investigated namely: Three Dimensional Printing - Drop-on-Bed from Z-corporation, Three Dimensional Printing - Drop-on- Drop from ThermoJet - 3D Systems and Selective Laser Sintering from EOS. Various RP/LM processes are discussed in detail and highlight the technologies selected in this study. A standard benchmark part, adapted from the European project framework FP6, designed and utilised in similar studies is used as the basis for the research. The Investment Casting process is discussed fully and compared to the Rapid Investment Casting, listing both the advantages and disadvantages of the above mentioned methods. In addition a special study has been conducted on investment casting of large components using layer manufactured patterns. This study not only helped to establish and validate the shrinkage value calculated for the aluminium castings but also showed substantial capability lacks in SA foundries to handle this type of components, which are by definition most often of high added value.

Published Article / Atkinson distinguishes between four types of prototypes, categorised through its end-use: •Design or aesthetic prototypes •Geometrical prototypes •Functional prototypes •Technological prototypes Shigley and Mitchell define the design process according to the following six phases: Recognition of need Definition of problem Synthesis Analysis and optimization Evaluation Presentation The Centre for Rapid Prototyping and Manufacture (CRPM) of the Central University of Technology, Free State was asked to assist in the development of a newly developed gynaecological cream applicator. Apart from needing a freeform fabrication system to give form fit and function to the very complex design, the product needed Rapid Tooling / Rapid Manufacturing support to enable a first batch production for medical trials and evaluation. The paper will describe the total product development process alongside prototype categories described by Atkinson and design phases defined by Shigley and Mitchell (including some iterations enabled through timeous prototyping, including various Rapid Prototyping (RP) Technologies, soft tooling and vacuum casting). More importantly, results from Rapid Tooling for limited run production (due to the complexity of the product the cycle time of the Prototype Tool is fairly long), as well as the economical impact made possible through the support of CAD / CAM and RP Technologies, will be discussed.

Published Article / Rapid tooling (RT) in the context of this research presents the possibility of improving the traditional investment casting process by shortening lead times while still maintaining affordable costs and required quality. Various rapid prototyping processes are available that can be used to create direct metal, polymer or wooden dies for this casting technology. This paper presents results gained in an AMTS project, focusing on RT development for investment casting of light metals. One of the most widely used layer manufacturing processes available in South Africa is selective laser sintering. A machine produced by the German manufacturer EOS (process known as laser sintering) utilising this technology was selected for the study. Two of the materials that are suitable for rapid die making are used, which in tum reflects different mechanical properties and process economics. A standard benchmark part was used as a study base. Two dies were built, one in alumide and one in polyamide. A comprehensive measurement programme was conducted, followed by an appropriate statistical analysis and evaluation regarding accuracy and surface finish. A number of wax patterns were produced. The best wax patterns from each die were selected and evaluated. The subsequently produced castings in AI, Mg and TI were further examined and evaluated. Various issues concerning the reinforcement, wax injection, pattern removal, accuracy and surface finish of the dies are discussed in the paper. The research concludes that rapid tooling techniques can be successfully used for creating accurate dies in order to shorten lead times in the investment casting process chain.

No description available.

Published Article / This paper surveys the current state and capabilities of Three Dimensional Printing (3DP). Based on its technical background - the ink jet printing as known from the printer and plotter industry - a classification structure has been developed and proposed. Different printing techniques and process concepts, together with their advantages and limitations are described and analysed. A large variety of manufacturing applications such as rapid pattern making and rapid tooling using the 3DP process directly or as core technology, as well as further implications in design and engineering analysis, medicine, and architecture are presented and evaluated. Some research issues are also discussed. An attempt, based on the state of the art, to show weaknesses and opportunities, and to draw conclusions about the future of this important process wraps up this paper.

Published Article / Global issues such as energy and climate changes have impacted on both the automotive and aerospace industries, forcing them to adopt measures to produce products that consume fewer combustibles and emit less carbon dioxide. Making vehicles lighter is one of the logical ways of reducing fuel consumption. The need for light components, able to fulfil technical and quality specifications, led to market growth for tooling that is able to mass produce parts using manufacturing processes such as high pressure die casting. Competitive pressures to reduce the lead time required for tooling-up has also increased dramatically. For this reason research into various methods, techniques and approaches to tool manufacture is being undertaken globally. This paper highlights the work undertaken at the CSIR on the issue of rapid die manufacturing through the application and evaluation of a rapid prototyping technique and coating technologies applied to die components of a high pressure casting die for the production of aluminium components. Criteria for determining suitability were developed against which the technique was evaluated that included time, cost and life-expectancy. Results of accelerated testing procedures to evaluate the die material produced by the rapid prototyping technique and surface coatings and treatments of die materials for their resistance to washout, erosion, heat checking and corrosion in a high pressure die casting environment, are presented. The outcomes of this research will be used for further development and application of specific techniques, design principles and criteria for this approach.