Research and development for industry: Advanced ... - CSIR

More documents

Recommendations

Info

DEFENCE SECTORSudesh Budram, a technical draftsman atthe CSIR, was instrumental in establishinga 3D-printing, rapid-prototyping and directmanufacturing capability.12Data from 2D sketches are used as input to create a 3D model.3A model is built from a high-performance composite powder, after which post-processing commences.4Removal of powder allows for final preparation of the model.The 3D model is inspected after the post-processing phase.| 44 |From drawing to tangible reality:The artful science of direct manufacturingCSIR clients can now benefit from a specialist capability that allows one to take a design, capture and simulate it digitally,and produce an actual, tangible object in hand. Previously known as rapid prototyping, direct manufacturing has changed themanner, and speed, by which a design can be turned into a physical prototype or model.Chris Serfontein headsthe CSIR’s technology forspecial operations group. Histeam focuses on technologysolutions to address the uniquerequirements of the SpecialOperations cadres in the SouthAfrican National Defence Force.In this field, rapidly created,custom and efficiently workingsolutions are critical. Accordingto Serfontein, the challenge hasalways been the time and costto produce the prototypes andproducts that can be providedto the client: “To date, manualand numerical-controlledmanufacture has been theoptions available to us,” hesays. “Direct manufacturingtechnology is now consideredmature and cost-effectiveenough to be procured as anextension to our capability.”Direct manufacture comprises:The stereolithographyapparatus (SLA) where alaser sets a layer of wax orphotosensitive material ina bath; three-dimensionalprinting (3DP), which usesinjection technology to createa thermo plastic structure;and selective laser sintering(SLS) that uses a laser to fusepowder (nylon, polycarbonate,polymer and metal).None of these, however, canbe used for colour terrainmodels. The CSIR thereforeprocured a 3D printer thatuses colour ink jet technology.Serfontein says that theprinter works like the normalprinter that one would useto print a photograph, exceptthat it does not print one layerper sheet of paper. “It printslayer upon layer, using amaterial that builds up on theprevious layer of material,” hesays, adding, “Each layer is a‘picture’ that slices throughthe object.”A frequent use of thisprinting capability is for thefinal production of 3D terrainproducts, based on the inputdata from CSIR geographicalinformation systems experts,clearly showing all aspectsof a terrain, as well as anyspecific information requiredby the client, in colour.The input into the 3DPhas to be created eitherin computer-aided design(CAD) software, or by usinga 3D scanner to capture alldimensions of a particularobject or shape.“CAD has for many yearsbeen able to turn thedesigner’s dream into acomputer model. This hasaided the design processsignificantly, but directmanufacture now givesthe designer the ability toproduce a complex modelquickly and affordably,”Serfontein says. This alsoenhances the advancedmechanical engineeringcapability, especially whencomplex mechanicalengineering solutions arerequired. The technologythus has obvious benefitsin terms of time-saving.It also reduces materialwaste associated withconventional forms ofmanufacture; lowersenergy use; and allows forthe design of unusual andmore organic shapes andforms.The designer can usedirect manufacturing toproduce the following:Scaled models of actualstructures, terrains, areas,prototypes of parts, actualitems (if a small volume isrequired and the material isacceptable); and as a highproductionvolume inputto investment casting (forpatterns), injection moulds(for hard tooling), sandmoulds, and soft tooling(for cores).Plans for the future are toexpand collaboration in thisfield and make the expertiseand facilities availablemore widely. Serfonteinsays that the CSIR is alsoworking closely with CentralUniversity of Technology(CUT), StellenboschUniversity and SoSolid inCape Town to build a nationalrapid prototyping and directmanufacturing capability.“CUT has shown interest incollaborating with the CSIRin rapid manufactureresearch, and sharingknowledge and capability,”he says, adding that CUT hasan extensive capability ofSLA, 3DP and SLS.“We want to create ashared direct manufacturecapability and service,including training with ournational partners,” Serfonteinconcludes.The capability is not restrictedto research and developmentefforts. It can be used byanyone who needs a designturned into an actual objectas a prototype, scale modelor test version. The teamcan, for example, createnovel shapes for artistic use,ceramic design and modelsfor architects or sculptors.Enquiries:Chris Serfonteincserfontein@csir.co.za| 45 |
DEFENCE SECTORCSIR experimentation in generatingbeams of exceptional brightness.World’s biggestoptics maker fixesits sights on CSIR lasersLaser partnership: From left, Dawie Mulder, project manager at Carl Zeiss, Dr Ndumiso Cingo, CSIRNational Laser Centre manager, Kobus Viljoen, managing director of Carl Zeiss and Prof AndrewForbes, CSIR chief scientist pictured after the signing of a year agreement at Carl Zeiss offices.| 46 |CSIR laser technology uptaketo see a new range of lasers forinternational optics producerThe CSIR recently signedan agreement with one ofthe largest optics producersin the world, Carl Zeiss,to customise a CSIRdevelopedlaser conceptfor a range of its lasers.According to CSIR chiefscientist and project leader,Prof Andrew Forbes, histeam and engineers from thePretoria-based company willattempt to incorporate theCSIR-designed and developedlaser resonator conceptinto their system. “Wehope to exceed the opticalperformance specificationswithout any fundamentalchanges to the systemdesign,” says Forbes. “It isworth noting that this workstarted in the laboratory as aproject funded through theCSIR’s parliamentary grant,resulted in published workin top journals and severalawards for the studentsinvolved as well as invitedlectures, and is now finding itsway into industry.”Forbes adds: “It is alwayspleasing when an idea eventuallymakes it to a technology thatis being taken up, especially byworld-leading specialists.” Thetechnology makes it possiblefor almost any laser to operatein a ‘high-brightness’ mode,resulting in more efficient lasersused in, for example, longrangecommunication systems,and in the military for targetdesignation.The collaboration between the twoorganisations is funded by CarlZeiss. The production plant for thelasers under development is locatedat Carl Zeiss’ facilities at Centurion,South Africa.“Such transfer of technology isnecessary for South Africa to growits knowledge-based economy,”says Forbes.The technology may also be usedto make lasers smaller and lessexpensive, by exploiting the extraefficiency to make the supportsystems work a little less.Managing directorof Carl Zeiss OptronicsSouth Africa, Kobus Viljoen,appreciates the relationshipthat his organisation enjoyswith the CSIR. He says thatthis healthy relationship spansmore than three decadesand took on varying forms oftechnology collaboration overthe years. This liaison hasbeen further strengthened bythe Department of Scienceand Technology’s strategyon photonics, the PhotonicsInitiative of South Africa(PISA).Viljoen’s comments followthe signing of a one-yearagreement between the twoorganisations. The agreementsees Carl Zeiss taking up alaser technology that wasdesigned and developed bythe CSIR mathematical opticsgroup. Carl Zeiss will use theapplication in its range ofoptical products.The conceptWith lasers one generally hasto choose between havinglots of energy and having a‘nice’ laser beam. A qualitythat incorporates both theseparameters is the so-called‘brightness’ of a laser: Highbrightness means good laserbeam quality and high energy.This is difficult to achievebecause good beams tend tocome at the expense of energy,while high-energy beams arehighly distorted and difficult touse in practical applications. Sois it possible to have the best ofboth worlds?Carl Zeiss Optronics designs,develops and producesstate-of-the-art optronicinstruments for militaryand civilian applications.Under the new Carl Zeissmanagement, revealsViljoen, the organisation isinvesting significantlyin new technologies.“We invest 10% of ourrevenue back into researchand development (R&D),”he notes.He adds, “We’ve reacheda stage where industrydefines the technology thatit wants. We will be usingthis technology in our nextgenerationproducts, suchas laser rangefinders andlaser designators – used inmissile guidance. We haveidentified an applicationarea where we neededtechnology and research,and the CSIR was able toprovide that.”A high-brightness laser explainedThe researchThe CSIR has for several yearsinvested in developing coreexpertise in shaping light withdiffractive optical elements;optics that have feature sizesdown to the micrometre scale,and sometimes to the nanometrescale.The idea is that given a laserbeam of a particular intensityprofile (i.e. how the energycarried by the laser is distributedin space), it is possible to reshapethe profile of this laser beam byredistributing the energy.If this is done correctly, then inprinciple any laser beam shapeHe says that this milestone is thetangible result of the PISA initiative.Dawie Mulder, project manager atCarl Zeiss, adds that the objectiveis to develop lasers that can beused in military applications. “Ourfocus is very much on productdevelopment – sometimes atthe expense of new technologydevelopment. Marrying the twois not an easy task,” says Mulder,“but successfully doing so can reallyhelp separate your products fromthe rest.”can be achieved. Thegroup worked on achievingthis same result, butinside a laser, so that thediffractive optical elementsare the mirrors of the laser.The idea was that if themirrors were correctlycalculated and thenfabricated, the laser itselfwould select the best beamfor maximum brightness.The shape of the laserbeam bouncing aroundinside the laser was chosento extract as much energyas possible from the laser,but in a ‘good’ shape.– Prof Andrew ForbesMulder elaborates, “TheCSIR is the single bestpool of knowledge in lasertechnology. It is a hugeadvantage for us to be ableto improve our products’performance and efficiencybased on the CSIR’s R&D.”– Mzimasi GcukumanaEnquiries:Prof Andrew Forbesaforbes1@csir.co.zaA Gaussian beam (top) for good beam qualityand a flat-top beam (bottom) for high energy.The CSIR produces a laser that combines both.| 47 |
Page 3 and 4: | |14Laser additive manufacturing24
Page 5: AEROSPACE AND AUTOMOTIVEThe Aerospa
Page 10 and 11: AEROSPACE AND AUTOMOTIVEParts cut o
Page 12 and 13: AEROSPACE AND AUTOMOTIVETrailersdes
Page 15 and 16: TOWARDS A NEW TITANIUM SECTORForgin
Page 17 and 18: TOWARDS A NEW TITANIUM SECTORGuests
Page 19 and 20: TOWARDS A NEW TITANIUM SECTORPerfec
Page 21: PHARMACEUTICAL AND CHEMICAL SECTORS
Page 28 and 29: ENABLING TECHNOLOGIESUsing locally
Page 30 and 31: ENABLING TECHNOLOGIESAhmed Shaik wi
Page 32 and 33: ENABLING TECHNOLOGIESThe CSIR’s D
Page 34 and 35: ENABLING TECHNOLOGIESCSIR experts i
Page 36 and 37: ENABLING TECHNOLOGIESDeveloping a|
Page 38 and 39: Commercialisation successes and opp
Page 40 and 41: SPECIALISED TECHNICAL SERVICES AND
Page 42 and 43: SPECIALISED TECHNICAL SERVICES AND
Page 44: | 84 |SPECIALISED TECHNICAL SERVICE

Research and development for industry: Advanced ... - CSIR

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?