A welcome addition

Imagine a mine site where any part can be imagined and then printed, on-site and on time, for immediate application.

3D printing is making that a reality.

Additive manufacturing (AM), a form of 3D printing, works by building a component layer by layer, as opposed to subtractive manufacturing where objects are created by reducing a block of material to a final product.

This enables the creation of lighter, stronger and more complex parts with less waste, offering additional benefits when it comes to specificity and scalability.

According to MIT, AM was first used to develop prototypes in the 1980s in a process known as rapid prototyping, allowing people to create a scale model of a final object quickly, without the typical setup process and costs involved in creating a prototype. By the early 2000s, additive manufacturing was being used to create functional products.

Compared to traditional manufacturing, relatively small amounts of components can be produced without resulting in significant losses. Similarly, components can be ‘printed’ very quickly, simply requiring a design created on a computer as a blueprint.

AM also allows for greater customisation and options when it comes to material selection, as each layer can use a different material if required.

While AM stands to transform manufacturing across fields, mining stands to reap many of the benefits.

The Australian Mining Review speaks with Curtin University, John de Laeter Centre (JdLC) Photon Forge Additive Manufacturing (PFAM) facility leader Dr Karl Davidson to uncover what the future of manufacturing could look like.

AM has the potential to revolutionise remote manufacturing of spare parts, tooling and hard-facing coating. It can support sovereign manufacturing capability and cut down on the lead time or supply chain disruptions that often crop up when parts need to be sourced from overseas.

AM also allows for ‘just-in-time’ manufacturing, where parts are only printed as and when they’re needed, doing away with the need for stockpiling.

“This has been a key driver for the Australian additive manufacturing machine companies such as AML3D and SPEE3D who have identified mining and other Australian industries such as maritime and defence as sectors of interest” Dr Davidson says.

“They have developed or are interested in developing remote manufacturing setups. This could look like a machine inside of a container that could be operated either at a mine site or even at sea.”

The Australian mining industry is already getting a glimpse into AM’s potential. For instance, LaserBond has used this method to successfully repair spindles on CAT dump trucks. By opting for repair over replacement, they’ve made notable cost savings while also ramping up operational efficiency.

The AM approach is shaking things up by producing parts that are a near match to their final design, slashing the need for excess machining or heat treatment.

Dr Davidson says AM has already unlocked significant savings.

“The advantage is a reduction in manufacturing time of about 65%, a reduction in material usage by about 20-50% and cost savings of 70% compared to conventional machining operations.”

All this is made possible by the greater design freedom provided by Curtin’s large format printers with deposition heads attached to six-axis robotic arms.

AM also offers unmatched scalability.

“AM uses a commercially standardised CNC programming,” Dr Davidson says.

“For operators trained on CNC machining processes, operation of AM equipment can be achieved through the same programming knowledge base”

“For scalability, one complete system can produce the part and then you can have a complete workflow, moving to the next stage of final machining and production.”

AM at Curtin university

The PFAM facility is a centralised hub for metal additive manufacturing at Curtin University under the direction of the JdLC. The facility is equipped with deposition based additive equipment for both small- and large-scale manufacturing, with the availability to process a range of alloy systems and benefits from the JdLC’s $50m of materials characterisation and testing equipment.

The PFAM facility assists research, development and training activities in additive manufacturing (AM) by leveraging existing material characterisation and analysis facilities, along with industrial collaborations. Cutting edge characterisation equipment at the JdLC complements the additive manufacturing process, enabling part quantification and characterisation.

The PFAM team conducts high quality research and engages with partners, both nationally and internationally, in government and industry to deliver targeted solutions to real world problems in the defence, mining, drilling, oil & gas, critical minerals and energy sectors.

In a landmark collaboration with the Additive Manufacturing Cooperative Research Centre (AMCRC), Curtin University is set to make significant strides in the world of 3D printing technology. The partnership aims to catapult the Technology Readiness Levels (TRL) from 6 to 9, laying the groundwork for impressive progress in sustainable manufacturing.

In the grand scheme of things, industry partnerships are vital for unlocking the full potential of AM. Curtin University and the JdLC have forged strong ties in industry with Wesfarmers, Fortescue, Austal, Woodside and others. These alliances are not just about research and development — they also provide internships, PhD fellowships and higher degree scholarships to students, moulding a workforce that’s ready to take on the industry.

Dr Davidson says these relationships help industry as companies can understand if the process will fit into their future or help them de risk the process.

“They don’t need to invest a huge amount of money into the technology,” he said.

“They can start a project and then work from there, identifying the suitability of AM for their processes.”

This sort of industry-driven research is key to propelling technologies like AM. Curtin’s approach is twofold: lend a hand to industries wherever possible, while also prepping students to fill roles within the workforce. This strategy has led to long-lasting and mutually beneficial relationships with industry partners.

Funded with $58m from the Federal Government’s Cooperative Research Centres program, the AMCRC will bring together 14 research partners and more than 50 industry collaborators to drive innovation, commercialisation and skills development over the next seven years.

Curtin University’s partnership with AMCRC is making real progress in propelling AM from prototype testing to full-blown production. The partnership is not only pushing the boundaries of sustainable manufacturing but also nurturing a highly skilled workforce ready to tackle the unique challenges of Australia’s mining sector.

The Curtin-based PFAM, under the stewardship of the JdLC, serves as a central hub for AM. It plays a crucial role in speeding up the transfer of innovation from applied research to practical applications and solutions. The facility offers a platform for researchers and industry professionals to develop and test cutting-edge AM solutions tailored to real-world problems in sectors such as mining, defence, drilling, oil & gas, critical minerals and energy.

But despite its many advantages, AM is still an emerging technology that needs further exploration. That’s why Curtin University is on the hunt for more industry partners to broaden its impact. By joining forces with mining companies on this innovative technology, Curtin aims to cut costs, boost efficiency and pave the way for a more sustainable future for the Australian mining industry.

Curtin University is open to engagement with the wider WA industry and is always looking for more industry partners to fuel innovation.