Using Idea-2-Product Labs® as a strategy for accelerating technology transfer

Technology transfer poses particular problems to developing countries whose governments cannot always afford to fund expensive high-tech solutions. This article reports on the Idea 2 Product Labs® concept that was developed in South Africa to offer a low-cost open-source alternative. The motivation behind the work was to put innovative new technologies into the hands of more people within a shorter timeframe than would otherwise be possible. The background, planning, objectives, outcomes and impact of the project are reported together with some conclusions on how this model could be adopted across a wider domain

Using additive manufacturing with blow moulding to facilitate accurate consumer testing

A South African entrepreneur needed a fast and accurate route to consumer testing for a design of phlegm collection bottle for long-distance runners. Vaal University of Technology was presented with an initial product concept which had to be developed into a fully functional prototype required for field trials. The idea was converted into a practical product proposal and modelled using a 3D computer aided design (CAD) system. The CAD data were used for laser sintering of polyamide to produce an initial prototype for appearance and ergonomic evaluation. For product testing in the field, a short run of fully functional prototypes in thin-walled low density poly-ethylene (LDPE) was required. This required a further design iteration and the production of tooling for the blow moulding process. A novel hybrid modular approach to tool manufacture was followed, where the outer frame of the tools were machined in aluminium and the tool inserts were laser sintered in AlumideTM. Blow moulding trials were undertaken in LDPE which revealed a number of positive and negative issues. The rough surface of the tool inserts produced a desirable textured surface in the resultant blow-moulded bottles but also prevented a clean “shut-off” between the two halves of the tool. This allowed air to escape from the cavity along the split plane, creating unwanted holes in the bottles. In addition, the low thermal conductivity of AlumideTM resulted in an unwanted overheating of the tools. Strategies were identified to overcome these issues and these are explained in the paper

The effect of acetone as a post-production finishing technique on entry-level material extrusion part quality

Entry-level material extrusion artefacts persistently suffer from questionable weakened end-product production quality, according to industrial standards. These limitations can be addressed by the development of improved finishing techniques that may narrow the gap between low-cost and high-end production methods in additive manufacturing. In doing so, the technology may become available to a larger spectrum of prosumers who previously were reluctant to use entry-level technology, because of these limitations. This article describes the effect that acetone has as a post-production finishing technique for low-cost artefact production. Through a serious of quantitative investigations, the study provides evidence that acetone reduces the tensile strength, increases polymer ductility and significantly reduces the surface profile roughness of thermoplastics such as acrylonitrile butadiene styrene. Potential cost and waste reduction for entry-level manufactured products are consequently identified

Using acetone (propanone) as a post-production finishing technique: Crossing the divide between art and technology

Entry-level Fused Deposition Modelling (ELFDM) is an ever-expanding technology being utilized in the art and design industries. As this level of additive manufacturing technology suggests, there are limitations to the production outcomes and quality of end products. A need exists to improve post-production finishing techniques that will assist with reducing limitations and enhance aesthetic value. This brings about a debate around the production quality and value of 3D printed artefacts. Acetone (propanone) has been identified in a conclusive study as a promising substance to assist with the post-production finishing of ELFDM artefacts. The paper presents investigations from a qualitative and quantitative perspective to demonstrate acetone’s impact on the aesthetic value and quality of artistic artefacts in the South African and international spheres. It demonstrates the influence of acetone on the tensile strength of ABS plastic, as well as the overall increased aesthetic value output of ELFDM produced artefacts. Further recommendations for future examination are also suggested to fast-track the development of this crucial component of the global art and design industries

Client-centred design evolution via functional prototyping

The product design process involves communication of potential design solutions to customers. Fully functional prototypes are most suitable for this because they are readily accepted and allow simultaneous evaluation of all design criteria. However, they are often seen as expensive, time-consuming and not fully representative of the final product material. Therefore, they are usually reserved for customer validation of the final design rather than to keep them involved in every product evolution iteration. This research proposes that rapid prototypes should be used to facilitate a method referred to as Customer Interaction through Functional Prototypes (CIFP). An action research methodology was employed to test the efficacy of applying this method to a real-world product design brief. Customers were able to fully evaluate the aesthetic, ergonomic and functional parameters of the product during every design iteration. This resulted in accelerated product development, sensitivity to the client's needs, a new dimension of 'natural' communication and a successful product design

Additive manufacturing of alumide jewellery

Additive Manufacturing (AM) has been used for various jewellery applications in the recent past - both through direct and indirect use of AM products. The typical trend for direct manufactured jewellery has however, been dominated by metals-based applications. Materialise, through their MGX collection, has helped to set a new trend of doing functional design / functional art through amongst others, direct laser sintered polymers. They have created a significant demand for direct manufactured products that are not possible to manufacture with conventional technologies. More importantly, some of these designs enable an element of personalisation, to lead to "bespoke art". Within a collaborative research project between De Montfort University (UK), Loughborough University (UK) and Vaal University of Technology (SA), one of the specific research outcomes was aimed at producing designs for direct AM jewellery in AlumideTM, an Aluminum and Nylon matrix. The objective was to go beyond complex shapes, to also create innovative techniques for insertion of gemstones in these designs, to result in limited production of "bespoke jewellery series". The paper and associated presentation will report on work in progress from the collaborative project, and will discuss first results, problem areas and future possibilities

Additive manufacturing as an enabler for enhanced consumer involvement

The proposed paper will draw on previous work done by the authors to use functional prototypes, produced using additive manufacturing (AM), as a means to draw customer input and preferences into new product development. This technique was referred to as Customer Interaction through Functional Prototypes (CIFP). The CIFP philosophy, as originally developed, has been proven both in consumer and medical products. In recent years, the authors have developed further concepts of AM-enabled enhanced consumer involvement within their respective research teams. The paper will discuss the extended use of CIFP in the VUT's Technology Transfer and Innovation Directorate to support grant holders of the Industrial Development Corporation (IDC) Support Programme for Industrial Innovation (SPII) and Technology and Innovation Agency (TIA) to develop innovative new product concepts. The paper will then go on to discuss a novel method of consumer interaction developed at Loughborough University referred to as Computer-aided Consumer Design (CaCODE). This technique allows non- designers to take an existing product design, e.g. a pen, and modify its shape, in real- time, until they create a customised version of the product that meets their needs. The modification is limited within pre-defined parameters to make sure that any final design is functional and producible using AM

Additive manufacturing as an enabler for enhanced consumer involvement

This paper draws on previous work by the authors that aimed to use functional prototypes, produced using additive manufacturing (AM), as a means to draw customer input and preferences into the development of new products. This technique is referred to as Customer Interaction through Functional Prototypes (CIFP). The CIFP philosophy has been proven in both consumer and medical products. In recent years, the authors have developed further concepts of AM-enabled enhanced consumer involvement within their respective research teams. This paper discusses the extended use of CIFP to develop innovative new product concepts in the Vaal University of Technology, to support grant- holders of the Industrial Development’s Corporation (IDC) Support Programme for Industrial Innovation (SPII) and the Technology and Innovation Agency (TIA). The paper goes on to discuss a novel method of consumer interaction developed at Loughborough University, referred to as a Computer-aided Consumer Design (CaCODE). This technique allows non- designers to take an existing product design (e.g., a pen) and modify its shape in real time, in order to create a customised version of the product that meets their needs. The modification is limited within pre-defined parameters to make sure that any final design is functional and can be produced using AM

Stereolithography build time estimation based on volumetric calculations

Purpose – Not all the inventors and designers have access to computer-aided design (CAD) software to transform their design or invention into a 3D solid model. Therefore, they cannot submit an STL file to a rapid prototyping (RP) service bureau for a quotation but perhaps only a 2D sketch or drawing. This paper proposes an alternative approach to build time estimation that will enable cost quotations to be issued before 3D CAD has been used. Design/methodology/approach – The study presents a method of calculating build time estimations within a target error limit of 10 per cent of the actual build time of a prototype. This is achieved by using basic volumetric shapes, such as cylinders and cones, added together to represent the model in the 2D sketch. By using this information the build time of the product is then calculated with the aid of models created in a mathematical solving software package. Findings – The development of the build time estimator and its application to several build platforms are described together with an analysis of its performance in comparison with the benchmark software. The estimator was found to meet its target 10 per cent error limit in 80 per cent of the stereolithography builds that were analysed. Research limitations/implications – The estimator method was not able to handle multi-component complex parts builds in a timely manner. There is a trade-off between accuracy and processing time. Practical implications – The output from the estimator can be fed directly into cost quotations to be sent to RP bureau customers at a very early stage in the design process. Originality/value – Unlike all the other build estimators that were encountered, this method works directly from a 2D sketch or drawing rather than a 3D CAD file