The Council for Scientific and Industrial Research (CSIR) has successfully produced 316L stainless-steel powder using a recently commissioned ultrasonic atomiser machine, co-funded by the National Research Foundation (NRF), an entity of the Department of Science, Technology and Innovation (DSTI). This machine produces high-quality powders that have the required particle size, flowability and density for use in additive manufacturing (AM), specifically for powder bed fusion techniques. Currently, South Africa depends on imports to access powders of this quality.

The ultrasonic atomiser machine is designed to make various metal powders from both reactive and nonreactive materials. Utilising this capability, the CSIR is positioned to provide, at a pilot scale, 316L stainless-steel powder to the South African market.

The powder production process involves meticulous characterisation using advanced analytical methods to ensure consistency in particle size distribution, flowability and packing density. These attributes are crucial for achieving the quality of the final 3D printed products.

Dr Miemie Maminza, who leads the Powder Metallurgy Technologies research group at the CSIR, elaborates on the importance of this development: "Our aim has been to create a sustainable local supply of high-quality stainless-steel powder, which currently has significant demand in the additive manufacturing space. Utilising our capabilities and expertise, we believe we can contribute to the establishment of locally produced powder to grow the AM industry. We are excited about the potential this holds for driving industrial growth and localisation."

Leveraging its expertise, the CSIR has successfully used its local atomised powder to 3D print prototype tools valuable for industrial use. The prototypes were manufactured using Hyrax, which was designed and manufactured by a local company called Aditiv Solutions.

Dr Ntombi Mathe, a principal researcher in AM at the CSIR, highlights the broader impact of these advancements: "By manufacturing our own metal powders and developing printers, we are fostering an ecosystem where innovation breeds economic empowerment; advancing in technology, supporting local businesses, and creating job opportunities. This approach leads to a cycle of positive economic growth and development."

Gerrie Lombaard, Director of Metal Heart expressed confidence that this powder meets industry standards and showed enthusiasm for switching to it, he stated, “After reviewing the report on the initial batch production of 316L stainless steel powder produced by the CSIR, Metal Heart has found the quality of this domestic powder to align with that of internationally sourced materials. The powder meets standards in aspects such as oxygen content, density, particle size and morphology. Therefore, Metal Heart is confident in using this powder for their production processes, anticipating no compromise in quality.”

This initiative is an integral part of a broader national agenda to drive localisation, reduce dependence on imports and enhance the technological capabilities of local industries. The DSTI has made substantial investments in growing the additive manufacturing value chain in all its dimensions. This includes advancements from an additive technology process perspective, such as design for additive manufacturing and AM machine building. Additionally, they have focused on the downstream, postprocessing aspects like surface heat treatment. Furthermore, they have targeted the upstream side by developing powder/feedstock and designing for circularity.

Beeuwen Gerryts, Chief Director of Technology Localisation, Beneficiation and Advanced Manufacturing at the DSTI, said, “The CSIR is to be congratulated on this milestone, which was achieved with DSTI and NRF funding, as this is an important step in helping to strengthen the upstream additive manufacturing value chain and to increase the local national capacity in powder processing. We look forward to receiving further positive feedback on how the technology can be scaled up to match industry demand at competitive prices.”
 

Media enquiries:

Kulani Chauke: Media Manager
Email: kchauke@csir.co.za or
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About the CSIR:

The CSIR, an entity of the Department of Science, Technology and Innovation, is one of Africa’s leading organisations in scientific and technology research, development, and implementation. Constituted by an Act of Parliament in 1945 as a science council, the CSIR undertakes directed and multidisciplinary research and technological innovation, as well as industrial and scientific development, to improve the quality of life of all South Africans.

This year, the CSIR celebrates 80 years of touching lives through innovation. For more information, visit www.csir.co.za

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