1. ADDITIVE MANUFACTURING PROJECT CLUSTER MEETING Polymer Additive Manufacturing (PAM) Fundació CIM C/Llorens i Artigas, 12 Parc Tecnològic de Barcelona Barcelona, Spain 2 May 2016 GJ Booysen & DJ de Beer Central University of Technology, Free State North West University Vaal University of Technology South Africa

2. Polymer Additive Manufacturing (PAM) Objectives: To develop new polymer AM materials through a localization approach so as to: Lower the cost of AM materials Supplement / broaden the range of materials to make provision for specific applications. Also attend to recycling of used materials. Aim: To assist industries to compete internationally. A decrease in consumable price will make a significant impact on local AM use, and can stimulate a value chain that contributes to economic development and job creation.

3. PAM: Exploitable Results ER 1 Business case and related tools for industrialisation of direct manufacturing using Polymer AM Processes ER2 Business case and related tools for industrialisation of indirect Polymer AM Processes ER3 Business case and related tools for the development of hybrid AM Processes

4. ER 1 - Business case and related tools for industrialisation of direct manufacturing using Polymer AM Processes Description of result and the resulting innovation Business case for the industrialization of applicable PAM processes to produce (customized or batch production of standard products),using topology optimization and part consolidation design/development processes: Consumer products; Industrial /manufacturing aids; jigs; fixtures; injection moulding and forming tools or inserts; robotic /mechatronic components; electronic manufacturing plant /assembly plan / robotic jigs and fixtures; complex industrial parts, tools or devices; Medical Products, e.g. Surgical Planning Models; Surgical Guides; Positioning Devices e.g. medical jigs, fixtures, clamps, etc., Surgery Tools or Assistive Devices, Medical Aids/Assistive Devices; Prostheses; Forming Tools, etc. Fashion, shoe ware, leather ware, accessories development for beneficiation of local raw materials Potential customers Trade and Industry, Government; Health Sector; Industrial Designers; Innovators and Entrepreneurs. Academia that wants to enrich their curriculum/keep it industry focused, or develop new research foci; Industrialists wanting to expand business horizons. Customer Benefits Innovative capacity and output; New business or enterprise development; Localized production and increased market share; Increased competitive capability, Reduction in costs; Reduction in errors; Increased turnover.

5. Technological Readiness Level: 6 - 8 in various projects Can easily progress to 9 Milestones in the TRL progression up to TRL 9: 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 : Costs and repayment/amortization costs of technology platforms (especially as a result of a weak exchange rate and predominantly imported equipment) leading to extremely expensive hourly rates; Limited material options / material property limitations; Costs of imported materials vs. lack of locally produced materials; Case study and resultant technology transfer costs; Local material development and qualification costs. Benchmarking problems (often as a result of competitive products and possible IP/in-house know-how) Time to market: Existing capacity for immediate (partial) implementation. Full implementation:12/2017 IPRs: Significant IPR potential in terms of product and process development; Trademarks and Design registration; licensing / selling of proprietary new material development. To be protected as progression / product/process realistion takes place. ER 1 - Business case and related tools for industrialisation of direct manufacturing using Polymer AM Processes

6. ER 2 - Business case and related tools for industrialisation of indirect Polymer AM Processes Description of result and the resulting innovation Business case for the industrialization of applicable Polymer Additive Manufacturing (PAM) processes to produce patterns for investment casting applications. Potential customers Trade and Industry, Government; Health Sector; Industrial Designers; Innovators and Entrepreneurs. Academia that wants to enrich their curriculum/keep it industry focused, or develop new research foci; Industrialists wanting to expand business horizons. 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.

7. ER 2 - Business case and related tools for industrialisation of indirect Polymer AM Processes Technological Readiness Level: Currently between 5- 6 in various projects (varying between participating institutions and application areas), e.g.: Design rules for Polymer-based investment casting designs- especially wrt minimum wall thicknesses; surface finish and infiltration; length to thickness ratios, ceramic coating; pattern burn-out; removal of ceramic after casting processes, etc. 5-6; Material choices wrt design, and mould crack prevention. 4-5 Focus on Design Topology Optimization for use in casting processes to minimize material use / reduce weight. 3-4 Milestones in the TRL progression up to TRL 9: 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 )

8. ER 2 - Business case and related tools for industrialisation of indirect Polymer AM Processes Main technical challenges in this result: Limited design and simulation experience; lacking AM material parameters for simulation; Developing of appropriate surface finishing techniques to compare with conventional processes; Costs and repayment/amortization costs of technology platforms (especially as a result of a weak exchange rate and predominantly imported equipment) leading to extremely expensive hourly rates; Development of a cost matrix for batch production; Limited material options / material property limitations; Costs of imported materials vs lack of locally produced materials; Case study and resultant technology transfer costs; Local material development and qualification costs. Benchmarking problems (often as a result of competitive products and possible IP/in-house know- how) Local material development costs Time to market: TRL 4 - TRL 5: 07/2017 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: Licensing of software packages or proven process methodologies; Design Registration; In-house know-how / “trade secrets” Transfer (selling/licensing) of production knowledge

9. ER 3 - Business case and related tools for the development of hybrid AM Processes Description of result and the resulting innovation Business case and related tools for the development of hybrid AM Processes that entails a matrix / composite structure of metal/polymer/ceramics. The proposed process entails serial growing of different materials to enhance soft tissue ingrowth on mainly metal-based bio-materials. In addition, growth of ceramics/bio-materials for medical usage will be an independent application. Potential customers Trade and Industry, Government; Health Sector; Industrial Designers; Innovators and Entrepreneurs. Academia that wants to enrich their curriculum/keep it industry focused, or develop new research foci; Industrialists wanting to expand business horizons. 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.

10. Technological Readiness Level: Currently between 2-4 in various projects (varying between participating institutions and application areas), e.g.: Growing process and design rules for ceramics-based designs- especially wrt minimum wall thicknesses; surface finish and infiltration;, etc. 2-3; Material choices wrt design, and composite development. 2-3 Focus on Design Topology Optimization to minimize material use / create scaffolds. 3-4 Serial growing of bio-materials /bio-ceramics on bio-metals such as Titanium to result in a composite structure: 2-3 Milestones in the TRL progression up to TRL 9: 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) ER 3 - Business case and related tools for the development of hybrid AM Processes

11. Main technical challenges in this result: Limited design and simulation experience; lacking AM material parameters for simulation; Costs and repayment/amortization costs of technology platforms (especially as a result of a weak exchange rate and predominantly imported equipment) leading to extremely expensive hourly rates; Limited material options / material property limitations; Costs of imported materials vs lack of locally produced materials; Case study and resultant technology transfer costs; Local material development and qualification costs. Benchmarking problems (often as a result of competitive products and possible IP/in-house know-how) Local material development costs Time to market: TRL 2 - TRL 3: 12/2016 TRL 3 - TRL 3: 07/2017 TRL 4 - TRL 5: 12/2017 TRL 5 - TRL 6: 07/2018 TRL 6 - TRL 7: 12/2018 TRL 7 - TRL 8: 07/2019 Full implementation with process qualification where applicable:12/2019 IPRs: Licensing of software packages or proven process methodologies; Licensing of software packages or proven process methodologies; Design Registration; In-house know-how / “trade secrets” Transfer (selling/licensing) of production knowledge Process IP Material development Design / Building management software ER 3 - Business case and related tools for the development of hybrid AM Processes

12. Expressions of Interest: PAM 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