There is a paucity of data on additive manufacturing process emissions and personal exposures in real-world workplaces. Hence, we evaluated atmospheres in four workplaces utilizing desktop “3-dimensional” (3-d) printers [fused filament fabrication (FFF) and sheer] for production, prototyping, or research. Airborne particle diameter and number concentration and total volatile organic compound concentrations were measured using real-time instruments. Airborne particles and volatile organic compounds were collected using time-integrated sampling techniques for off-line analysis. Personal exposures for metals and volatile organic compounds were measured in the breathing zone of operators. All 3-d printers that were monitored released ultrafine and fine particles and organic vapors into workplace air. Particle number-based emission rates (#/min) ranged from 9.4 × 109 to 4.4 × 1011 (n = 9samples) for FFF3-d printers and from 1.9 to 3.8 × 109 (n = 2 samples) for a sheer 3-d printer. The large variability in emission rate values reflected variability from the printers as well as differences in printer design, operating conditions, and feedstock materials among printers. A custom-built ventilated enclosure evaluated at one facility was capable of reducing particle number and total organic chemical concentrations by 99.7% and 53.2%, respectively. Carbonyl compounds were detected in room air; however, none were specifically attributed to the 3-d printing process. Personal exposure to metals (aluminum, iron) and 12 different organic chemicals were all below applicable NIOSH Recommended Exposure Limit values, but results are not reflective of all possible exposure scenarios. More research is needed to understand 3-d printer emissions, exposures, and efficacy of engineering controls in occupational settings.

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Purpose -The last decade has seen major advances in rapid prototyping (RP), with it becoming a multi-disciplinary technology, crossing various research fields, and connecting continents. Process and material advancements open up new applications and manufacturing (through RP) is serving non-traditional industries. RP technology is used to support rapid product development (RPD). The purpose of this paper is to describe how the Integrated Product Development research group of the Central University of Technology, Free State, South Africa is applying various CAD/CAM/RP technologies to support a medical team from the Grootte Schuur and Vincent Palotti hospitals in Cape Town, to save limbs -as a last resort at a stage where conventional medical techniques or practices may not apply any longer. Design/methodology/approach -The paper uses action research to justify the proposal of a new method to use CAD/CAM/RP related technologies to substitute lost/damaged bone regions through the use of CT to CAD to.STL manipulation. Findings -A case study where RP related technologies were used to support medical product development for a patient with severe injuries from a road accident is discussed. Originality/value -The paper considers current available technologies, and discusses new advancements in direct metal freeform fabrication, and its potential to revolutionise the medical industry.

The Rapid Product Development Association of South Africa (RAPDASA) expressed the need for a national Additive Manufacturing Roadmap. Consequentially, the South African Department of Science and Technology commissioned the development of a South African Additive Manufacturing Technology Roadmap. This was intended to guide role-players in identifying business opportunities, addressing technology gaps, focusing development programmes, and informing investment decisions that would enable local companies and industry sectors to become global leaders in selected areas of additive manufacturing. The challenge remains now for South Africa to decide on an implementation approach that will maximize the impact in the shortest possible time. This article introduces the concept of a national Additive Manufacturing Centre of Competence (AMCoC) as a primary implementation vehicle for the roadmap. The support of the current leading players in additive manufacturing in South Africa for such a centre of competence is shared and their key roles are indicated. A summary of the investments that the leading players have already made in the focus areas of the AMCoC over the past two decades is given as confirmation of their commitment towards the advancement of the additive manufacturing technology. An exposition is given of how the AMCoC could indeed become the primary initiative for achieving the agreed national goals on additive manufacturing. The conclusion is that investment by public and private institutions in an AMCoC would be the next step towards ensuring South Africa's continued progress in the field. OPSOMMINGDie "Rapid Product Development Association of South Africa" (RAPDASA) het die behoefte aan 'n nasionale toevoegingsvervaardigingpadkaart uitgelig. Gevolglik het die Departement van Wetenskap en Tegnologie opdrag vir die ontwikkel van so 'n padkaart gegee. Hierdie was veronderstel om rolspelers te lei in die identifisering van besigheidsgeleenthede, die aanspreek van tegnologie tekortkominge, die fokus op ontwikkelingsprogramme en om beleggingsbesluite te beïnvloed wat plaaslike maatskappye en industrieë in staat sal stel om wêreldleiers op uitgekose areas van toevoegingsvervaardiging te word. Die uitdaging vir Suid-Afrika is nou op 'n toepassingsbenadering wat die maksimum impak in die kortste moontlike tyd sal verseker. Hierdie artikel stel die konsep van 'n nasionale Toevoegingsvervaardiging Sentrum van Bevoegdheid as 'n primêre toepassing van die padkaart voor. Die ondersteuning deur die hoof rolspelers in Suid-Afrika vir so 'n sentrum word gedeel en hulle onderskeie rolle is aangedui. Die rolspelers se toewyding word gestaaf aan die hand van hul beleggings in die fokus areas van die Sentrum oor die laaste twee dekades. 'n Uiteensetting word verskaf van hoe die Sentrum inderdaad die hoof inisiatief vir die behaal van die ooreengekome nasionale doelstellings kan word. Die gevolgtrekking is dat belegging deur # This article is an extension of a paper presented at

Type of Paper General Review PurposeIn a previous Rapid Prototyping Journal paper, the authors reviewed the first decade of Rapid Prototyping (RP) use within the Republic of South Africa (RSA). The paper analysed its strengths, weaknesses, opportunities and threats, and proposed a "road-map" for future development. Much has happened in the intervening years since that article was published and this paper seeks to update readers on the current situation in RSA. In particular, it reports the extensive development of research in the field of RP and Additive Manufacturing (AM). MethodologyThe paper uses a literature review approach combined with reflective analysis to distill the most important developments within the RP community in RSA since 2004. These are compared to the previous road-map to ascertain if there are any required actions that have been overlooked or any additional lessons that have been learnt. FindingsThe paper shows that there has been good progress against the previous road-map and that current plans should remain in place with the addition of a greater educational dimension. Practical ImplicationsThis paper provides readers with an overview of important RP/AM developments in the RSA.The analysis from this the paper will aid RSA academics, industrialists and government agencies to assess their performance and to plan for their future roles within the RP community. ValueAs with the previous paper, this article provides a useful model for other countries to follow since it demonstrates both good practice but also the need to learn from past experience.

Purpose In this era of Fourth Industrial Revolution, also known as Industry 4.0, additive manufacturing (AM) has been recognized as one of the nine technologies of Industry 4.0 that will revolutionize different sectors (such as manufacturing and industrial production). Therefore, this study aims to focus on “Additive Manufacturing Education” and the primary aim of this study is to investigate the impacts of AM technology at selected South African universities and develop a proposed framework for effective AM education using South African universities as the case study. Design/methodology/approach Quantitative research approach was used in this study, that is, a survey (questionnaire) was designed specifically to investigate the impacts of the existing AM technology/education and the facilities at the selected South African universities. The survey was distributed to several students (undergraduate and postgraduate) and the academic staffs within the selected universities. The questionnaire contained structured questions based on five factors/variables and followed by two open-ended questions. The data were collected and analyzed using statistical tools and were interpreted accordingly (i.e. both the closed and open-ended questions). The hypotheses were stated, tested and accepted. In conclusion, the framework for AM education at the universities was developed. Findings Based on different literature reviewed on “framework for AM technology and education”, there is no specific framework that centers on AM education and this makes it difficult to find an existing framework for AM education to serve as a landscape to determine the new framework for AM education at the universities. Therefore, the results from this study made a significant contribution to the body of knowledge in AM, most especially in the area of education. The significant positive responses from the respondents have shown that the existing AM in-house facilities at the selected South African universities is promoting AM education and research activities. This study also shows that a number of students at the South African universities have access to AM/3D printing lab for design and research purposes. Furthermore, the findings show that the inclusion of AM education in the curriculum of both the science and engineering education is South Africa will bring very positive results. The introduction of a postgraduate degree in AM such as MSc or MEng in AM will greatly benefit the South African universities and different industries because it will increase the number of AM experts and professionals. Through literature review, this study was able to identify five factors (which includes sub-factors) that are suitable for the development of a framework for AM education, and this framework is expected to serve as base-line or building block for other universities globally to build/develop their AM journey. Research limitations/implications The survey was distributed to 200 participants and 130 completed questionnaires were returned. The target audience for the survey was mainly university students (both undergraduate and postgraduate) and the academics who have access to AM machines or have used the AM/3D printing lab/facilities on their campuses for both academic and research purposes. Therefore, one of the limitations of the survey is the limited sample size; however, the sample size for this survey is considered suitable for this type of research and would allow generalization of the findings. Nevertheless, future research on this study should use larger sample size for purpose of results generalization. In addition, this study is limited to quantitative research methodology; future study should include qualitative research method. Irrespective of any existing or developed framework, there is always a need to further improve the existing framework, and therefore, the proposed framework for AM education in this study contained only five factors/variables and future should include some other factors (AM commercialization, AM continuous Improvement, etc.) to further enhance the framework. Practical implications This study provides the readers and researchers within the STEM education, industry or engineering education/educators to see the importance of the inclusion of AM in the university curriculum for both undergraduate and postgraduate degrees. More so, this study serves as a roadmap for AM initiative at the universities and provides necessary factors to be considered when the universities are considering or embarking on AM education/research journey at their universities. It also serves as a guideline or platform for various investors or individual organization to see the need to invest in AM education. Originality/value The contribution of this study towards the existing body of knowledge in AM technology, specifically “AM education research” is in the form of proposed framework for AM education at the universities which would allow the government sectors/industry/department/bodies and key players in AM in South Africa and globally to see the need to invest significantly towards the advancement of AM technology, education and research activities at various universities.

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.

Background Emerging reports suggest the potential for adverse health effects from exposure to emissions from some additive manufacturing (AM) processes. There is a paucity of real-world data on emissions from AM machines in industrial workplaces and personal exposures among AM operators. Methods Airborne particle and organic chemical emissions and personal exposures were characterized using real-time and time-integrated sampling techniques in four manufacturing facilities using industrial-scale material extrusion and material jetting AM processes. Results Using a condensation nuclei counter, number-based particle emission rates (ERs) (number/min) from material extrusion AM machines ranged from 4.1 × 10 10 (Ultem filament) to 2.2 × 10 11 [acrylonitrile butadiene styrene and polycarbonate filaments). For these same machines, total volatile organic compound ERs (μg/min) ranged from 1.9 × 10 4 (acrylonitrile butadiene styrene and polycarbonate) to 9.4 × 10 4 (Ultem). For the material jetting machines, the number-based particle ER was higher when the lid was open (2.3 × 10 10 number/min) than when the lid was closed (1.5–5.5 × 10 9 number/min); total volatile organic compound ERs were similar regardless of the lid position. Low levels of acetone, benzene, toluene, and m,p -xylene were common to both AM processes. Carbonyl compounds were detected; however, none were specifically attributed to the AM processes. Personal exposures to metals (aluminum and iron) and eight volatile organic compounds were all below National Institute for Occupational Safety and Health (NIOSH)-recommended exposure levels. Conclusion Industrial-scale AM machines using thermoplastics and resins released particles and organic vapors into workplace air. More research is needed to understand factors influencing real-world industrial-scale AM process emissions and exposures.