3D printing to create precision-engineered mining equipment

Anticipated to run over a three-year period, the research alliance covers the first phase of a project to research solutions that will revolutionise how composite polymers are used to manufacture mineral separation equipment and create new manufacturing technologies. UTS will house all project work at a new additive manufacturing (AM) facility at its Broadway campus to network and brainstorm various conceptual ideas.

Located in the UTS Faculty of Engineering and IT, the project will be undertaken with Rapido, a unique rapid prototyping unit established in 2016 to help industry, government and community partners translate innovative ideas and complex problems into viable products and solutions. Herve Harvard, Director of Rapido, says the unit seeks research partnerships to engage staff and students in innovative projects that help to bridge the gap between industry and universities. Two PhD students will be allocated to the Downer/IMCRC project and mentored throughout its lifecycle.

“Partnering with Rapido harnesses a unique capability in terms of the breadth and depth of expertise and advanced facilities we have at UTS,” said Harvard. “This project demonstrates how UTS is becoming a leading university in AM and, in this particular context, leading in the capability to develop bespoke 3D printing technologies suitable for manufacturing functional parts.”

Alex de Andrade, Mineral Technologies’s Global Manager – Sales, Equipment and Technology, is an associate professor with UTS and will provide industry partner leadership to the project. He said the project is aligned with Mineral Technologies’s strategic technology roadmap as it focuses on delivering AM products with embedded Internet of Things (IoT) connected sensors. These sensors will direct operators to optimal set point recommendations in real time.

“This project will define an accelerated deposition and curing technique for AM which will hasten the way in which composite polymers are deposited to manufacture our mineral separation equipment, in particular, gravity spirals,” said de Andrade. “We expect to see positive environmental impacts, such as decreasing the need for chemicals and reducing air contamination, which will significantly improve the operational environment for our manufacturing workforce.”

It is anticipated that the new AM methods will attract the next generation of engineers and workforce who will become skilled at setting up 3D printers as well as profile programming and CAD meshing development. David Chuter, IMCRC’s CEO and Managing Director, pointed out that applying AM technologies will not only revolutionise the manufacturing process of mineral separation equipment but the associated supply chain operations, especially when the equipment is fitted with IoT sensors.

“Mineral separation equipment is often operated in a remote and hostile environment,” said Chuter. “Deploying gravity spirals fitted with IoT sensors will offer Mineral Technologies a clear picture of the product performance. We also see that this innovative manufacturing approach and research could yield benefits for other sectors, such as vertical agriculture and other applications.”