History Of CAD in South Africa
As with all nations, South
Africa (RSA) has a unique set of circumstances and challenges. Emerging from
economic isolation and stagnation, South Africa has some highly developed
regions but also some pockets of poorly developed infrastructure. Therefore,
developing countries can learn from the way it has sought to modernise its
industries and to look for guidance. In relation to technology, South Africa has
embraced rapid prototyping (RP) as a method of revolutionising its industry.
According to du Preez et al., (2006), the first RP systems were installed in
South Africa in 1994. Since then, its uptake has advanced rapidly.
The use of RP and related technologies, such as computer
aided design (CAD) and rapid tooling (RT) has grown rapidly in the RSA. Between
2005 and 2006, the total number of RP machines installed doubled (Wohlers,
2006, 2007). Growth slowed down between 2007 and 2008 to around 24% and 21%
respectively (Wohlers, 2008, 2009). In recent years, RP and RT technologies
have been joined by AM as designers began to embrace the advantages that could
bring geometric freedom in small batch production. A key enabler for the uptake
of AM has been the broadening of the technologies available, such as Direct
Metal Laser Sintering (DMLS) which was introduced to the Central University of
Technology (CUT), Free State in 2006. Practitioners and researchers have been
pushing boundaries every year, with new developments and case studies being
reported. Although all of the major universities have a strong presence in
manufacturing research, AM-related research is being driven by a minority
(39%), whilst some more have AM facilities used to support other manufacturing
research, giving a total of 48% of universities having AM facilities in-house.
Figure 1 Basic 3D Printing Machine
The rise of 3D printers has seen a wide variety of industries becoming involved in additive manufacture, probably as a result of South Africa’s National R&D Strategy which has attempted to draw SMMEs (Small, micro and medium-sized enterprises) into the country’s Innovation network. This trend illustrates that technology transfer programmes from universities to industry with government support have paid off.
Whereas more universities in South Africa are becoming involved in RP/AM research, the University of Stellenbosch and the CUT are still the current leaders. Research has been focused towards new materials and improving machine accuracy. Research teams have also investigated novel industrial applications where little or no previous research had been done.
Medical applications involving the use of RP techniques have advanced within South Africa through a combination of CT and MRI scanning, reverse engineering, RP/AM and computer numerical control (CNC) machining. Collaborative development work between the CUT and a team of surgeons and biomedical engineers have resulted in several innovative projects. They include patient-specific X-ray shielding masks (de Beer et al, 2005b), customised manufacture of medical prosthetics (Truscott et al, 2007), elbow implants fabricated using CNC (Figure 5) and cranial implants produced directly out of Titanium alloys using Selective Laser Melting at CUT, as reported by Drstvensek, et al. (2009).
For medical applications, RP technologies were used because of the relatively low mechanical stresses presented and also because of the high aesthetic demands that were required. Current research is now focused towards Direct Laser Sintering of Titanium that would yield benefits in terms of material utilisation, optimised geometry and reduced lead-time. Another area of research developed from a collaborative partnership between CUT and Loughborough University in the United Kingdom concerned the application of customer interaction with 9 functional prototypes (CIFP). It saw the development of a new range of motion analysis accessories produced directly from Laser Sintering.
The use of RP technologies have increased the fidelity of physical models in terms of aesthetics, ergonomics and functionality. The results have facilitated greater customer participation during product development and allowed ideas to be tested to reduce the risk of failure in the market (Campbell et al, 2007).
The rise of 3D printers has seen a wide variety of industries becoming involved in additive manufacture, probably as a result of South Africa’s National R&D Strategy which has attempted to draw SMMEs (Small, micro and medium-sized enterprises) into the country’s Innovation network. This trend illustrates that technology transfer programmes from universities to industry with government support have paid off.
Whereas more universities in South Africa are becoming involved in RP/AM research, the University of Stellenbosch and the CUT are still the current leaders. Research has been focused towards new materials and improving machine accuracy. Research teams have also investigated novel industrial applications where little or no previous research had been done.
Medical applications involving the use of RP techniques have advanced within South Africa through a combination of CT and MRI scanning, reverse engineering, RP/AM and computer numerical control (CNC) machining. Collaborative development work between the CUT and a team of surgeons and biomedical engineers have resulted in several innovative projects. They include patient-specific X-ray shielding masks (de Beer et al, 2005b), customised manufacture of medical prosthetics (Truscott et al, 2007), elbow implants fabricated using CNC (Figure 5) and cranial implants produced directly out of Titanium alloys using Selective Laser Melting at CUT, as reported by Drstvensek, et al. (2009).
For medical applications, RP technologies were used because of the relatively low mechanical stresses presented and also because of the high aesthetic demands that were required. Current research is now focused towards Direct Laser Sintering of Titanium that would yield benefits in terms of material utilisation, optimised geometry and reduced lead-time. Another area of research developed from a collaborative partnership between CUT and Loughborough University in the United Kingdom concerned the application of customer interaction with 9 functional prototypes (CIFP). It saw the development of a new range of motion analysis accessories produced directly from Laser Sintering.
The use of RP technologies have increased the fidelity of physical models in terms of aesthetics, ergonomics and functionality. The results have facilitated greater customer participation during product development and allowed ideas to be tested to reduce the risk of failure in the market (Campbell et al, 2007).
Figure 2 3D Printed prosthetic
The increasing choice of materials available has positively influenced industry‟s acceptance of AM, According to Professor Dimitri Dimitrov, Head of the University of Stellenbosch’s Laboratory for Rapid Product Development (LRPD), the use of technologies such as 3D printing is cost-effective, versatile, fast and easy to operate (Dimitrov, 2006). In addition, its accuracy, strength, surface finish, build speed and cost, allow a good price to performance ratio. The findings are in-line with Haskins (2008) who also reported that digital technologies integrated with 3D printing enable a fast, affordable way to produce physical prototypes directly from CAD data.
Figure 3 Materials
South Africa‟s technology transfer strategy has been generally successful with more companies embracing RP/AM technology and buying machines. Indeed, the growth of RP purchases within industry is now well above that seen in academia (de Beer, 2008). Most of these have been 3D printers but some high end systems have also been purchased. At the same time, the growth in the use of digital tools such as CAD and RP software is evidenced by increased system sales, as seen by Materialise for their offerings. Further growth in the use of CAD could be expected if its use within South African schools become mainstream. This is one of the aims spearheaded by the DesigNation initiative launched in 2005 by the National Product Development Centre (NPDC) of the CSIR. However, the NPDC ceased to exist due to internal restructuring of the CSIR, and the initiative continued with only limited success until 2007.
