ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING Design for Additive Manufacturing (DfAM) Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain 2 May 2016 Prof DJ de Beer North West University Vaal University of Technology South Africa

Design for Additive Manufacturing (DfAM) Objective: To develop a design methodology centered on the unique manufacturing capabilities of additive manufacturing technology. Background: To enable South African industry to develop world-class products through optimized design methodologies.

DfAM: Exploitable Results ER 1 New Knowledge / Expertise for Industry Partners- Improved Design Capabilities that can lead to locally designed optimised products. Local direct manufacturing and indirect manufacturing opportunities of both bespoke (limited) and complex parts- limited and batch production opportunities. ER2 Design and FEA Toolkit or guidelines for various AM platforms, AM materials and growing styles or parameters as inputs for specific increased product design and product functionality or increased designer capabilities, e.g. Conformal Tooling Design; Part Consolidation; Weight Reduction and Material Minimisation with simultaneous increase in strength and parallel cost reduction. Current focus is on Design for AM using various Polymer processes (FDM, LS, Inkjet printing of polymers and ceramics, Poly-Jet printing, etc.), in addition to Metals processes (DMLS), with medical; aerospace; tooling, jigs, guides, surgical or experimental models, casting patterns, consumer products, prostheses and assistive devices, etc., as earmarked applications.

DfAM: Exploitable Result 1 Description of result and the resulting innovation Creation of a design optimization process, which results in predominantly skills development, so as to create an innovative service and/or innovation / innovation product development capability. Potential customers Individuals wanting to enhance their personal skills; Academia that wants to enrich their curriculum and short course portfolio; Industry that wants to train / retrain existing staff, but simultaneously want to apply this ability/expertise to increase innovation output and produce innovative new products, optimize production as a result, lower costs, increase market share and as such, higher turnovers. Customer Benefits Innovative capacity and output; New business or enterprise development; Localized production increased market share; Increased competitive capability, Reduction in costs; Reduction in errors; Increased turnover.

DfAM: Exploitable Result 1 Technological Readiness Level: in various projects Can easily progress to 9 Milestones in the TRL progression up to TRL9: 6-7: Benchmarking: Proving the capabilities through applicable/repeatable case studies; 7-8: Prototype production and testing (one-offs or batch production, dependent on the nature of the product) of new, innovative products. 8-9: Producing innovative, final, repeatable production batches that contributes to local production of new and innovative products that makes technological, financial, environmental and social contributions. Main technical challenges in this result : Software acquisition and training costs Case study and resultant technology transfer costs Benchmarking problems (often as a result of competitive products and possible IP/in-house know-how) Time to market:. Full implementation:12/2016 IPRs: Virtually no IPR involved in this ER – more based on in-house skills and know-how, in parallel with licensing of enabling software

DfAM: Exploitable Result 2 Description of result and the resulting innovation Creation of design rules for different AM Platforms, Processes or Materials and parameters to impact on part quality and strength, to impact on applications / applications areas Potential customers Individuals wanting to enhance their personal skills; Academia that wants to enrich their curriculum and short course portfolio; Industry that wants to train / retrain existing staff, but simultaneously want to apply this ability/expertise to increase innovation output and produce innovative new products, optimize production as a result, lower costs, increase market share and as such, higher turnovers. In addition, there is a significant medical, social and quality of life impact, together with a social entrepreneurship component. Customer Benefits Innovative capacity and output leading to new products; New business or enterprise development; Localized production and increased market share; Increased competitive capability, Reduction in costs; Reduction in errors; Increased turnover, and on the opposite of the value chain, issues such as increased quality of life, health-related aspects, etc.

DfAM: Exploitable Result 2 Technological Readiness Level: Currently between 2- 6 in various projects (varying between participating institutions and application areas), e.g.: Design rules for Polymer-based processes in high-end / high value addition applications: 2-3; Development of FEA parameters for polymer processes: 2-3; Design rules for: Polymer-based medical applications such as surgical guides, medial jigs/holding guides, etc.: 3-4; Metals-based medical applications : 3-4; Metals-based tooling applications: 4-5; Ceramics (sand) for casting processes: 5-6; Polymers for investment-casting processes: 5-6 Milestones in the TRL progression up to TRL9: Technology Concept Formulated (2-3) Experimental proof of concept (3-4) Technology Validation in Industry applications (4-5); Technology Demonstration through repeatable case studies (5-6); Technology validation through real-life industrial applications, including design, simulation, optimization, inspection, testing measuring and NDA (6-7); Qualification processes where applicable (7-8); Final operational applications (8-9)

DfAM: Exploitable Result 2 (c’td) Main technical challenges in this result: Development of suitable industrial / real-life case studies Case study and resultant technology transfer costs Benchmarking problems (often as a result of competitive products and possible IP/in-house know-how) Time to market: TRL 3 - TRL4: 12/2016 TRL 4 - TRL 5: 06/2017 TRL 5 - TRL 6: 12/2017 TRL 6 - TRL 7: 06/2018 TRL 7 - TRL 8: 12/2018 Full implementation with process qualification where applicable:07/2019 IPRs: IPR may be vested in: Licensing of software packages or proven process methodologies; Design Registration; In-house know-how / “trade secrets” Transfer (selling/licensing) of production knowledge

Expressions of Interest: DfAM M2-US-EXOVA M5-SA-FORMING M6-SA-MEDAERO M13-EU-AATID PB2-SA-POLYAM PB3-EU-RAPIDOS GT7-MX-CIATEQ GT8-MX-UASLP GT10-EU-CAXMAN GT11-EU-FOFAM GT13-EU-CASSAMOBILE