HIGH SPEED, LARGE VOLUME ADDITIVE MANUFACTURING MARIUS VERMEULEN ADC AEROSWIFT

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 www.aerosud.co.za 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) High-speed, large volume Additive Manufacturing

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

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.”

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

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 3D 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 Blade tenon rebuild Leading edge erosion repair Turbine journal repair

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

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)

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

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)

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

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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