Additive Manufacturing Categories Processes

8/10/2019 Additive Manufacturing Categories Processes

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Thursday, 23 August 2012

ADDITIVE MANUFACTURING CATEGORIES PROCESSES

AND MATERIALS

There are several different categories and processes of additive manufacturing

available, each appropriate for different materials and requirements. These are

detailed in the diagrams below.

Powder bed processes consolidate thin layers of powder using a laser or electron

beam to fuse scans of the sliced Computer Aided Design (CAD) data to create

the geometry. A re-coater mechanism is used to lay down the powder on top of

each scanned area, allowing you to build up the part layer by layer.


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Material Deposition/Extrusion processes work by heating the material through an

extrusion nozzle which follows a predefined deposition path, layering on top of aplatform, depositing material on top of previous layers to create the

3-dimensional geometry. For metallics blown powder and wire extrusion can be

used, however the material is melted at using a laser or electron beam at source.


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3D printing works by laying down thin layers of heated material onto a platform.

Either the head or platform will continuously be moving to deposit more material

on top of each other to form the 3D object. Binders and powder can also be used

to form 3D objects.

The liquid vat process solidifies thin layers together, using an ultraviolet (UV)

curable thermo set polymer liquid with a solid state crystal laser to create the

required geometry layer by layer, using Computer Aided Design (CAD) data. Are-coater mechanism is used to cover the previous layer with the material

enabling the next layer to be scanned.


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CURRENT SUPPLIERS OF AM EQUIPMENT:

Company web address Location

EOS GmbH (www.eos-gmbh.de) Germany

envisiontec GmbH (www.envisiontec.de) Germany

SLM Solutions (www.slm-solutions.com) Germany

MK (www.mk-technology.com) Germany

VOXELJET (www.voxeljet.de) Germany

Concept Laser GmbH (www.concept-laser.de) Germany

ExOne GmbH (www.exone.com) Germany

Stratasys (www.stratasys.com) USA

ZCorp (www.zcorp.com) USA

3DSystems (www.3dsystems.com) USA

Solidscape (www.solid-scape.com) USA

Optomec LENS (www.optomec.com) USA

Sciaky (www.sciaky.com) USA

Solidica Inc. (www.solidica.com) USA

EWI (www.ewi.org/) USA

Inovati Inc. (www.inovati.com) USA

CenterLine Limited (www.supersonicspray.com) Canada

Objet (www.objet.com) Israel

MTT/MCP/HEK (www.mtt-group.com) UK


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Phenix Systems (www.phenix-systems.com) France

Obninsk (www.licenz.ru/eng/) Russia

fcubic ab (www.fcubic.com) Sweden

Arcam AB (www.arcam.com) Sweden

Sulzer Metco (www.sulzermetco.com) Switzerland

MORE DETAIL ON CURRENT AM PROCESSES:

1. SELECTED LASER MELTING

With Selected Laser Melting these powder layers (see materials below) are selectively

melted under an inert gas atmosphere with a precisely controlled laser which produces

excellent component surface finish, tolerances and resolution.

Subsequent annealing and heat treatment can produce mechanical properties

comparable to wrought materials.

Materials that can be currently laser deposited:

Stainless steel

Cobalt-Chrome alloys

Titanium alloys

Bronze-nickel alloys

Tool steelsNickel based super alloys

Further research opportunities in SLM:

Investigating mechanisms of residual stress build up and finite element modeling

Measurement of as built residual stress

Parameter development for increase build rate

Parameter development for improved down facing surface finish


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Mechanical property validation together with build position and parameter effects

Micro structural evolution and modeling

Manufacture and quantification of complex net structures

Deposition of new and novel materials

2. ELECTRON BEAM MELTING

E-beam manufacturing is carried out hot and under a vacuum. This enables the

production of fully dense, highly complex geometries in reactive and traditionally

difficult to manufacture materials. This near net shape technique can drasticallydecrease residual stress, machining time, material costs, manufacturing steps

and lead time. In addition to this, geometries that cannot be manufactured by any

other manufacturing process can easily be achieved with this technique.

Materials that can be currently E-beam deposited:

Titanium alloys

Cobalt-Chrome alloysTitanium aluminides

Nickel based super alloys

Aluminium

Tool steel

Stainless steel

Hard metals (including Tungsten)

Amorphous metals

CopperNiobium

Beryllium

Further research opportunities in EBM:

Improvements in as deposited surface finish

Mechanical property validation together with build position and parameter effects

Micro structural evolution and modeling


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Grain refinement in titanium alloys

Manufacture and quantification of complex net structures

Deposition of new and novel materials

Machine development

3. AEROSOL JET DEPOSITION

Aerosol Jet Deposition is a high resolution printing technology for layer deposition

onto flat or complex 3D substrates. Advantages of this system include capability

for printing micrometric features (


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A wide range of novel materials with exceptional properties can be produced by

SPS including nano structured components, gradient composites, transparent

ceramics, textured materials and near net shape parts.

Sinteringis a method used to create objects from powders. It is based on atomic

diffusion. Diffusion occurs in any material above absolute zero, but it occurs

much faster at higher temperatures.

In most sintering processes, the powdered material is held in a mould and then

heated to a temperature below the melting point. The atoms in the powder

particles diffuse across the boundaries of the particles, fusing the particles

together and creating one solid piece.

Because the sintering temperature does not have to reach the melting point of the

material, sintering is often chosen as the shaping process for materials with

extremely high melting-points such as tungsten and molybdenum.

Sintering is traditionally used for manufacturing ceramic objects, but finds

applications in almost all fields of industry. The study of sintering and of

powder-related processes is known as powder metallurgy. A simple, intuitiveexample of sintering can be observed when ice cubes in a glass of water adhere

to each other.

5. METAL INJECTION MOULDING

Metal Injection Moulding (MIM) is a powder metallurgy process used to produce

small complex components.

Metal Injection Moulding opens up a whole new set of uses for alloys previously

seen as difficult to machine, non-castable or unable to be forged.

A batch of metal powder mixed with a special binder, is heated and injected into a

rigid mould cavity. Once the part is released from the mould, the binder is


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removed by either a solvent or thermal process. Finally the part is sintered in a

furnace to achieve near full density, typically >95% dense and with a high degree

of dimensional accuracy.

MIM has a wide area of applications which include, radial rotors, turbocharger

rotors, automotive parts, surgical tweezers, gas manifolds, jet engine levers, fuelnozzles, watch cases, jewellery etc.

Solid state processing nature gives MIM parts mechanical properties and

chemical uniformity comparable and even superior to the parts manufactured via

the more conventional routes. MIM opens up a whole new set of uses for alloys

previously seen as difficult to machine, non-castable or unable to be forged. This

is especially true for high temperature alloys used in turbine components.

Our vacuum sintering furnace makes it possible to process just about any type of

metal powder. Combined with the ability to manufacture toolsets, we can offer acomplete development programme.

POTENTIAL CRC MODELS

What we could offer:

The AMCRC could provide the following services to SME manufacturers:

Additive Manufacturing Technology an introduction

Systems, materials, benefits, and costs comparison for manufacturing

Is additive manufacturing right for your products and processes?

Build an additive manufacturing part

Prototype for proof of design or to show to customers

Mass customisation for manufacturing

Improvements on hybrid and existing manufacturing methods

Alternative manufacturing routes or processes


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Computer Aided Design for AM

Design modification for AM

Preparing and nesting partsReverse engineering / scanning for manufacturing

Defining and analysing AM parts

Materials analysis and testing

Non destructive testing

Destructive testing

Engineer to engineer AM workshop

Hands on design and build experience

Business specific follow on

Tailored training courses

Fully defined, costed and delivered research projects

Direct project with business

Material development

Collaborative project (partially funded)

Process and system developments

Software creation for manufacturing

One option could be to offer Australian SMEs an amount of free impartial advice

and information, and/or subsidised part manufacture using AM technologies,

depending what is best for their business.


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Materials Characterisation

Materials characterisation plays an important role in understanding the

relationship between component manufacture and performance. Therefore a

central element to a future Additive Manufacturing Cooperative Research Centre

will be extensive material characterisation capabilities centred around near net

shape powder based manufacturing.

The AMCRC should offer a comprehensive choice of materials characterisationcapabilities including:

microstructure analysis

surface finish assessment

chemical composition analysis

crystallographic information

sample preparation

The AMCRC could comprise existing research participants equipment plus new

state of the art equipment such as:

Scanning Electron Microscopes (SEM)

Transmission Electron Microscopes (TEM)

Optical Microscopes

Electron Microprobe

X-ray Photoelectron Spectroscopy (XPS)Glow Discharge Optical Emission Spectroscopy (GDOES)

Scanning Probe Microscope (SPM)

Cathodoluminescence (CL)

Along with these characterisation facilities the AMCRC should have a dedicated

team of staff who are experienced in providing services to commercial clients.

State of the art computer modelling


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A comprehensive range of modelling software could be applied to the analysis of

traditional forging and casting techniques, as well as to state of the art powder

metallurgy.

ABAQUS hot and cold deformation processes, heat transfer, fluid dynamics

SysWELD weld simulation to predict and control distortion and residual

stresses

ProCAST casting simulation including mould filling, solidification processes,

microstructure and thermo-mechanical properties

Capabilities also include: metal flow, prediction of final geometry of product,

shrinkage, segregation and phase transformations.

Using our proposed modeling capability you can reduce the cost and time to

develop new products and processes

The AMCRC could determine the top 50 Australian manufacturing SMEs likely to

benefit from additive manufacturing. We would develop specialist knowledge of

additive manufacturing and a wide range of general technology and engineering

knowledge. We would work with SMEs to determine if additive manufacturingcan add value to their business.


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The role of Direct Digital Manufacturing in the transformation of the

production and innovation system

The desire to offer custom-made mass products which becomes possible by

using DDM is not new. Production on demand, co-production, agile

manufacturing, additive manufacturing, modern manufacturing or mass

customisation is only some of the keywords referring to the same ideas:

Mass production has passed its peak and production processes have to be more

flexible, serving the individual consumer perfectly. Taking this into consideration

new business models started to be developed at the turn of the century.Just-in-time production and deliveries save storage and guarantee a flexible

reaction to demand fluctuation. Nowadays, with the help of new communication

and manufacturing technologies, new dimensions of flexibility can be reached.

Up until now a sustainable development approach has not been paramount when

considering these concepts - companies simply wanted to increase productivity

and open up new market potentials.

In contrast to the traditional series manufacturing concept (sequentially addedproduction steps), the concept of interactive co-production is an effective way of

designing products for the customer. Hastings research in the early 90s on the

organisation of dynamic project teams (abolishing rigid hierarchies, where

communication patterns are narrowly defined, in order to build up role orientated

teams instead, which can react quickly to new market demands), is valuable for

breaking down boundaries today: Breaking down the wall between company

(inside) and the customer (outside). Separations are fading more and more,

when considering for example in the renewable energy market (solar panels on

private roofs).

The digital age allows quick data exchanges and provides convenient

3D-construction software for plenty of people, while additive manufacturing like

SLS allows a quick, tool-less, plug & play production of highly customised design

parts. The symbiosis of those technologies has already led to innovative

business models in the dental industry: The scanned data of a tooth is sent to a

company, which sinters the custom made replacement quickly. The next


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generation of business models will combine additive manufacturing and

open-innovation concepts to gain even more insights and flexibility regarding

customer requirements.

Besides the development which is still governed by large capital intensiveindustrial companies and take place top down from industry to customer, there

are also some strong and viral bottom-up movements based on the idea of

autonomous, local and personalised innovation and fabrication as well as

collaboration and democratisation (instead of competition) as a driver of

progress. FabLabs, personal fabricators and self-repair-communities are some

shapes of this movement.

The idea of FabLabs started in 2002 at the MIT.

Small groups of people engage in open and collaborative high-tech workshops to

individualise design, products and new manufacturing processes. The equipment

of a FabLab typically consists of 3D-printer, laser cutter and milling machine.

Nowadays more than 100 FabLabs worldwide are operating. There are none in

Australia however SA is likely to start the first. The first German FabLab started

as late as 2009 at the Aachen University.

Surprisingly, this development is not restricted to developed countries only, but

also takes place in Africa and Asia - even Afghanistan possesses a FabLab.

Therefore the idea of FabLabs affects one of the main ideas of sustainable

development: balancing human welfare, fairness and participation on a global

scale.

DDM and especially 3D-printers based on Fused Deposition Moulding (FDM) are

the technological backbone of the FabLab movement. In 2008 the first low price

3D-printer named RepRap was released. The RepRap is sold as a construction

kit: Most of the parts can be 3D-printed (one of the main ideas of fabbing is

self-replication of production machines). The other parts are easily available in

each construction store. The RepRap (GB) was followed by the MakerBot (US) in

2009, the Ultimaking (NL) and the ShaperCube (D) in 2011. Three further

3D-printers, Fabbster (D), iRapid (D) and MakiBot (Cn) were announced for 2012.

Prices decreased at the same time from about US$2000 to US$300.


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No matter whether top-down industrial mass customisation or the bottom-up

democratization of production will be the dominant driver in future, DDM

technologies will spread with high speed through industry and society.

Nevertheless, individualised small scale production lacks in efficiency. In a broad

study on energy efficiency of various manufacturing technologies Allwood et al.

showed that at process rates below 10 kg/h energy efficiency decreases by

magnitudes. At 0.1 kg/h efficiency decreases by a factor of 1000. Values for

injection moulding (high process rates) and laser sintering and melting (low

process rates) prove these findings. This shows clearly that if FabLabs and

especially personal fabricators are supposed to positively contribute to

sustainable development they have to overcome todays constraints of lowefficiency in small scale and early product life cycle stages. Taking into

consideration the fast spreading of 3D-printers during the last four years this is of

great importance.

A production scenario based on personalised additive manufacturing sometimes

is assumed to reduce transport.

But this will only be true when locally available materials are used for theproduction of things and the personal fabricator itself. But nowadays construction

kits and materials are sold worldwide.

Materials for personal fabrication available today are mainly based on fossil

acryonitrile butadiene styrene (ABS). But with polylactic acid (PLA) a promising

biobased alternative has already entered the market. The quality of the surface of

the parts produced may achieve 30 m which is poor compared to injection

moulding.

Thinking in terms of consumer products one of the most interesting properties of

polymers is their ability to mould all kinds of surface structures such as polished

surfaces or leather-like surfaces. Therefore either the acceptance of rough

surfaces or technologies to finish them have to be developed. Otherwise

DDM-products will be placed in technical surroundings (e. g. under the hood) but

they do not interact directly with the consumer.


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In regard to recycling, Gutowski and Dahmus showed that there is an apparent

boundary which defines if whether recycling makes sense or not. Low dispersion

of materials and high overall material values of the product favour recycling.

Today the recycling of plastic bottles and steel cans make sense even at low

overall material values because dispersion is very low. In contrast computerrecycling despite an overall material value of about 1 billion dollars does not

make sense since the degree of material dispersion is too high. Therefore the

utilisation of only few materials and the ease of disassembling should be an

important technical guideline for future developments of the personal fabricators

and the components produced with this technology.

Unfortunately the current problems in personal fabrication addressed by the

community are dominated by lack in technical functionality only (speed, resolutionand the limited availability of different colours, materials and 3D-models).

Aspects of sustainability (e. g. resource use) are not mentioned except for some

concerns about volatile emissions assumed to have toxic effects caused by

thermal degradation of the printing material.

Significant sustainability effects are expected in terms of product longevity. As

the consumer is responsible for the design of the sintered products and

components, he will probably not throw them away thoughtlessly. The sameeffects are well known, when it comes to self manufactured or home-made items.

This deeper psychological connection between customer and consumer good

leads to a more careful handling.

Furthermore repairing complex products and producing spare parts will become

easier. Life cycles of complex products could extend decisively as many items

are thrown away today because no spare parts exist or repairing them is too

expensive.

Conclusions

Over 1.7 billion people worldwide now belong to the consuming class. It is

expected that in 2050 about 4 billion people will share the life style of the

developed countries. Nevertheless, regarding resources and emissions this will

simply not be possible. In order to reduce the ecological footprint of consumption

decisively, the whole system of producing and consuming thus needs


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to be innovated.

Based on a foresight-process report of 2009, the research field

ProductionConsumption2.0 became an important issue in the funding activities

of the German Federal Ministry of Education and Research. The change ofmaterial flow patterns, and especially the paradigm shift to personalized

production, e.g. in generative processes is one important driver for the new

research field.

Unfortunately different players and stakeholders in this field up until now neither

reflect the needs of sustainable development nor include it in their action plans.

The dominant SLS-technology lacks in energy efficiency and recyclability, light

weight potentials are limited because suitable materials are not available.Within more than 100 FabLabs we did not find one with a strong focus in

sustainability.

Nevertheless, participation, collaboration and self fabrication increase the

responsibility of everybody which should be an excellent base for a sustainable

consumer producer- relationship. It revives the idea of the traditional locally

established handicraft business without rejecting the process of globalisation and

the use of high tech methods. Its high time for the first sustainable FabLab!


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The AMCRC will determine the top 50 - 75 Australian manufacturing SMEs likely

to benefit from additive manufacturing. We need to then understand the

aggregate research challenges for this group. We will work with SMEs to

determine if additive manufacturing can add value to their business.

The following analysis has been completed to determine target companies:

Potential Industry Participants

1. Professional and Scientific Equipment Manufacturing

Activity

(ANZSIC code)

Description Major Companies

(market share %)

Photographic,

Optical and

Ophthalmic

Equipment

Manufacturing(2411)

This class consists of units mainly

engaged in manufacturing

photographic equipment (except

sensitised photographic film, paper,

plates or chemicals), opticalinstruments or equipment, or

ophthalmic equipment. Also included

are units mainly engaged in grinding

optical lenses.

Redflex Holdings(VIC) 9.1%

Carl Zeiss Vision (VIC) 8.1%

Ellex Medical Lasers(SA)

5.8%

Medical &

Surgical

EquipmentManufacturing

(2412)


engaged in manufacturing medical,

surgical or dental equipment,including dentures.

ResMed Holdings(NSW)

28.5%

Baxter Healthcare(NSW)16.2%

Abbott Australasia(NSW)

14.2%

Other

Professional

& Scientific

Equipment



navigational, measuring or other

professional and scientific equipment

Agilent (Australia) Pty(VIC)

12.6%

Danaher Australia Holding

Pty Ltd(VIC) 7%


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Manufacturing

(2419)

not elsewhere classified such as

control or meteorological or surveying

equipment or instruments, or

specialised parts for such equipment.

Thales Australia(NSW)

5.7%

2. Computer and Electronic Equipment Manufacturing

Activity

(ANZSIC code)


(market share %)

Computer and

Electronic

Office

Equipment

Manufacturing

(2421)



computers, computer peripheral

equipment or other electronic office

equipment.

Acer Computer Aust.

Pty(NSW) 5 %

Leader Computers Pty

Ltd(SA) 1%

Impact Systems

Technologies Pty Ltd

Communication

Equipment

Manufacturing(2422)



electronic and/or studio equipmentfor television or radio broadcasting;

data transmission equipment, such

as routers or modems; or

telecommunication (including

telephone) data communication,

receiver or transceiver equipment.

Codan Limited (SA) 3.1%

GPC Electronics(NSW) 3%

SRXGlobal(NSW) 3%Triasx Pty Ltd (NSW) 1.5%

OtherElectronic

Equipment

Manufacturing

(2429)

This class consists of units mainlyengaged in manufacturing audio or

visual receiving sets, sound

reproducing and/or recording

equipment, radio receiving sets

(except radio transceivers or radio

telegraphic or telephone receivers),

television receiving sets,

Cochlear Limited(NSW) 34%BAE Systems(SA) 13.5%

SRXGlobal (NSW) 6%

Gaming machines:

AristocratLeisure(NSW)

27.4%

Ainsworth(NSW(13%)


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headphones, electronic equipment

or components not elsewhere

classified. Includes gaming

machines

3. Electrical Equipment Manufacturing

Activity

(ANZSIC code)


(market share %)

Electric Cable

and Wire

Manufacturing

(2431)


engaged in manufacturing cables,

wires or strips capable of

conducting electricity, including

braided or insulated non-ferrous

cables, wires or strips. Units mainly

engaged in manufacturing optical

fibre cables for data transmission,

including telecommunicationscables are also included.

Nexans Australia(VIC) 30.2%

Prysmian(NSW) 12.5%

Australia Pacific Electrical

Cables(QLD) 2.7%

Corning Cable Systems(VIC)

2.4%

Electric

Lighting

Equipment

Manufacturing

(2432)


engaged in manufacturing light

bulbs, tubes or fittings (except

automotive) or electric signs

Gerard Lighting Group(SA)

29.5%

Legrand Minitronics (NSW) 4%

Outdoor Elements (VIC)3.2%

Other

Electrical

Equipment

Manufacturing

(2439)



batteries, electric motors,

generators, electricity transmission

or distribution equipment,

switchgear, switchboards,

Century Yuasa Batteries (QLD)

43.7%

Exide Australia(SA) 35.1%

Battery Energy(NSW) 4%


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transformers or other electrical

machinery, equipment, supplies or

components not elsewhere

classified.

4. Domestic Appliance Manufacturing

Activity

(ANZSIC code)


(market share %)

Whiteware

Appliance

Manufacturing

(2441)



domestic electric, electronic or gas

whiteware appliances. Whiteware

includes domestic cooking,

refrigeration, freezing or washing

appliances. Also included are units

mainly engaged in manufacturingfood waste disposal units or

barbecues

Electrolux (NSW) 21.3%

Rheem Australia(NSW) 16.8%

GWA Group(NSW) 6.2%

Hastie Group(NSW) 6%

5. Pump, Compressor, Heating and Ventilation Equipment Manufacturing

Activity

(ANZSIC code)


(market share %)

Pump and

Compressor

Manufacturing

(2451)


engaged in manufacturing air or

gas compressors, pumps or

pumping machinery (except

refrigeration or air conditioning

compressors or parts).

Weir Group(NSW) 24.8%

Flowserve Australia(VIC) 8.2%

Danaher Australia(NSW) 6.3%


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Fixed Space

Heating,

Cooling and

VentilationEquipment

(2452)



commercial or industrial fixed

space heating, cooling and airconditioning equipment (except

motor vehicle air conditioners) or

specialised parts for such

equipment. Also included are units

mainly engaged in manufacturing

commercial or industrial gas

heating equipment, refrigerateddisplay counter units or vending

machines

United Technologies(VIC)

30.8%

Daikin Australia(NSW) 10.6%

Seeley International(SA) 6.7%Heatcraft Australia(NSW) 4.9%

6. Specialised Machinery and Equipment Manufacturing

Activity

(ANZSIC code)


(market share %)

Agricultural

Machinery

and

Equipment

Manufacturing

(2461)



agricultural machinery or

equipment, tractors for agricultural

purposes (except crawler tractors),

lawn mowers or specialised partsfor such equipment.

Victa 3.5%

Honda Motorcycle and Power

Equipment (VIC) 2%

Silvan Australia(VIC) 2%

AF Gason(VIC) 1.5%

Mining and

Construction

Machinery

Manufacturing

(2462)



construction, earthmoving or

mining machinery and equipment,

or specialised parts for such


Atlas Copco(NSW) 11.2%

Bradken Limited(NSW) 7.6%

Boart Longyear(SA) 6.5%

Caterpillar(VIC) 3.2%


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mainly engaged in manufacturing

crawler tractors and tractors for

construction or earthmoving

purposes.Machine Tool

and Parts

Manufacturing

(2463)



woodworking or metalworking

machinery or equipment, or

specialised parts for such


mainly engaged in manufacturingpneumatic or power operated hand

tools, dies or die sets.

ANCA Pty Ltd (VIC) 11.4%

Thermadyne Australia(VIC)

6.3%

Marand Precision

Engineering(VIC) 4.1%

Dimas(SA) 3.2%

Tuppaware (VIC) 1.5%

Other

Specialised

Machinery

and

Equipment

Manufacturing

(2469)



specialised machinery and

equipment not elsewhere classified

or parts for such equipment not

elsewhere classified. Includes food

processing machinery

Schneider Electric(NSW)

13.4%

Wilson Transformer(VIC) 5.8%

ABB Australia(NSW) 4.8%

Food processing:

Moffat Group (VIC)14%

7. Other Machinery and Equipment Manufacturing

Activity

(ANZSIC code)


(market share %)

Lifting and

Material

Handling

Equipment

Manufacturing

(2491)


engaged in manufacturing forklift

trucks, cranes, winches, hoists or

hoisting equipment, conveyors or

conveying systems, materials

handling equipment not elsewhere

classified, or specialised parts for

Sandvik (QLD) 27.4%

United Technologies(VIC)

21.7%

KONE Holdings(NSW) 12.4%

Crown Equipment(NSW)

10.6%

Clark Equipment(NSW) 7%


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such equipment. This class also

includes units mainly engaged in

manufacturing elevators,

escalators or lifts, or inmanufacturing tractors not

elsewhere classified.

Other

Machinery

Equipment

Manufacturing

(2499)



machinery and equipment or parts

for such equipment not elsewhere

classified.

ABB Australia(NSW) 19%

Pall Filtration (NSW & VIC)

2.5%

Automotive Components

Limited (TAS & QLD) 1.2%

8. Metals Manufacturing

This generally relates to manufacturing metals from raw metal ores, primarily via

smelting and refining processes.

9. Metal Casting and Forging

This generally relates to making metal products from metals by casting (melting and

pouring in a mould) or forging (using machinery with hammering/pressing action) to

produce metal shapes of specific forms. This occurs at foundries (casting) or forges

(forging).

Activity

(ANZSIC code)


(market share %)

Iron and steel Make cast iron or steel products 367 businesses:

7 large businesses (~50%)


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casting

(2121)

Iron and steelforging

(2210)

by casting (e.g. tubes, pipes) and

forging (e.g. rail lines). The

industrys main products are iron

and steel tubes, pipes, vehicleparts (doors, frames, exhaust

pipe, etc) and railway, machinery

and mining infrastructure.

Except big businesses, firms tend

to operate in either casting or

forging (not both).

- Bradken

- Tyco Flow Control

- Castle Harlan Australian

Mezzanine (Intercast &Forge)

- CMI Industrial (Engineered

Components, Toowoomba

Metal Technologies)

- Crane Group (Crevet)

- Ajax Foundry

- Beverley Industries 360 small businesses (31%)

OneSteel (19%)

Make castings and forgings

primarily of aluminium, and also

copper, zinc and lead. The

industrys main products are

aluminium castings for the

automotive industry (e.g. wheels,

transmission, gear boxes) and

copper tubes, pipes, rods and

wires for use in electrical

appliances and plumbing.

Business typically specialise in

one product.

This sector includes aluminium

castings made by pouring molten

metal into a mould, or by

die-casting (injecting molten

metal into a mould).

83 businesses:

5 medium business (~50%)

- Arrowcrest (John Shearer,

ROH Wheels)

- Mett Diecasting

- Melbourne Gravity

- Lenlok

- Mullins Wheels

78 small business (~50%)


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10. Metal Product Manufacturing

This generally relates to making metal products of primary shapes (e.g. tubes, sheets,

bars) from metals (ingots) using processes other than casting and forging. This

includes processes such as rolling (passing metal through rollers), drawing (pushing or

drawing metal through a die to squeeze the metal into a thinner, longer shape)

extruding (pushing or drawing metal through a die to make products of a defined

cross-section).

Activity

(ANZSIC code)

Description Companies

(market share %)

Steel pipe and

tube

manufacturing

(2122)

Make seamless or welded steel

or ferrous pipes and tubes using

methods other than casting or

forging (e.g. cold drawn pipes).

235 businesses (46%) e.g.

- Hills Holding (Orrcon)

-Stainless Tube Mills

OneSteel (54%) not eligible

(STP)Aluminium

rolling,

drawing,

extruding

(2142)

Make aluminium sheets, rods,

bars, pipes, plates, tubes, wire,

powder, flakes and foil. This is

done by hot or cold rolling,

drawing or extruding. The

industrys main products are

aluminium sheets or shapesused in transport, construction,

packaging or household items,

as well as aluminium rods and

extruded sections (e.g.

construction bars, wheels).

56 businesses:

2 big businesses (36%)- Capral

- Alcoa Australia Rolled

Products

Other businesses:

- Ullrich Aluminium

- GJames Extrusion Co- Almax Aluminium

- Independent Extrusions (InEx)

- Extrusions Australia

- Extrusions Profile Australia

- Aluminium Shapes

(AluShapes)

Other basic Rolling, drawing or extruding129 businesses:


27/45

non-ferrous

metal product

manufacturing

(2149)

non-ferrous metals, other than

aluminium, into primary shapes.

Industrys major products are of

copper: mainly pipes and tubes(for plumbing and heating), also

wires (for electrical applications),

rods and bars (for home exterior

construction e.g. shingles,

gutters, downspouts).

1 big business (45%)

- MML (MM Kembla)

Others, e.g. Crane Group (4%)

11. Fabricated Metal Product Manufacturing

This generally relates to making intermediate or end-use metal products from metals

by various metal-working processes (forging, stamping, bending, forming, machining

and welding). A wide variety of products are made by these businesses.

Activity

(ANZSIC code)


(market share %)

Structural

metal product

manufacturing

(222)

This includes making:

structural steel components

(beams, joists, bars, steel

wire/mesh) for incorporation

in buildings & other

structures.

pre-fabricated metal buildings

(bus shelters, carports,

garages, sheds, etc)

architectural aluminium

products (doors, railings,

gates, window frames,

shower screen frames,

garage doors, shutters, etc)

~2,000 businesses:

Bigger businesses include:

- Capral

- JELD-WEN

- Boral

- Alesco

- Valmont (Webforge)

- Airport Doors

- Permasteelisa

- Gliderol

- Mirage Industries

- Acrow Formwork & Scaffolding

- Centurion Garage Doors

- Modular Metals


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metal roofing and guttering

architectural steel, wrought

iron or other metal products

(staircases, balconies,

window frames, decks etc)

Not included: assembly of

complete pipelines or steel

towers (construction)

OneSteel and Bluescope Steel

are not eligible (STP)

Metal

container

manufacturing(223)


heavy gauge containers

(metal boilers, superheaters,

farm storage tanks, gas

cylinders, metal vats, silos)

other aluminium, steel and tin

cans, canisters, drums,

collapsible tubes or metal

containers (beverage & food

cans, aerosol cans, steel

pails, steel boxes, shippingbarrels & drums)

>100 businesses:


- Amcor- Pratt

- Impress Australasia

- National Can Industries

Sheet metal

product

manufacturing

(224)


a large range of productsfrom sheet metal (air ducts,

guttering, bottle lids, can lids,

sanitary ware products, bins

& hoppers, vehicle numberplates)

1,775 businesses, many small

Bigger businesses (18%)

- GWA Group

- Hills Holding

- Amcor

- National Can Industries

Bluescope Steel (12%) noteligible (STP)

Other

fabricated

metal product


spring or wire products for

use in construction, mining,

>6,000 businesses


- ACME Operations

- Noza


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manufacturing

(229)

agriculture and automotive

manufacturing (barbed wire,

metal baskets, conveyor

belts, cable wire, chain link

fencing, fence gates, nails,shopping trolleys, wire rope

and cable, steel nails,

staples, tacks, spikes, fence

gates, heavy & light gauge

springs, etc)

nuts, bolts, screws, rivets,

other fasteners and washers

for construction andmachinery, equipment,

automotive and aircraft

manufacturing

providing metal finishing

services (coating, engraving,

enamelling, lacquering,

varnishing, galvanising,

anodising, etching, coating,colouring). This does not

include galvanising or tinning

of steel sheet or strip.

other fabricated products

(boilers, water meters, door

handles, bathroom fittings,

locks, firearms, ammunition,

safes, etc)

- Valmont

- PPG Industries

- Locker Group

- Neumann

- Pacific Steel- Tru-Test

- Hills Holding

- Thales

OneSteel is not eligible (STP)

Note:

Several companies undertake both metal manufacturing and mining activities:

Iron ore mining (including iron ore dressing, beneficiating)


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Bauxite mining

Copper ore mining (including copper ore leaching)

Gold ore mining (including unrefined gold bullion production, dredging, ore

roasting and flotation extraction and metallurgical hydro-extraction, gold

washing or sluicing, re-working mullock heaps or tailings for gold) Mineral sand mining (including mining of ilmenite, leucoxene sand, rutile sand,

monazite sand and zircon sand, and synthetic rutile production).

Nickel ore mining

Silver-lead-zinc mining

Other metal ore mining

Polymer Product Manufacturing

This generally relates to manufacturing of intermediate or end-use plastic products for

consumer goods or for use in construction. These products are often made through

blow and injection moulding or plastic extrusion processes.

Natural Rubber Product Manufacturing

This generally relates to the manufacture of products derived from natural rubber.

Activity

(ANZSIC code)


Natural

Rubber

Product

Manufacturing

(1920)


Products made solely from

natural rubber (bath mats,

condoms, conveyor belts,

dummys, hoses, hot water

bottle, mattress protector,

rubber balloons, sponges,

177 businesses

Ludowici

Fenner Dunlop

Vulcanite

Nylex


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pillows cushions)

12. Pharmaceutical and Medicinal Product Manufacturing

This generally relates to the manufacture of various medicinal and pharmaceutical

products for humans and animals.

Activity(ANZSIC code)

Description Companies(market share %)

Human

Pharmaceutical

and Medicinal

Product

Manufacturing

(1841)


Pharmaceutical and medicinalproducts for human use from

both natural (plants) and

synthetic sources (chemicals).

These include antibiotics,

vitamins, vaccines etc.Diagnostic substances for

antibodies, antigens and

chemical diagnostic testing

agents

318 (ANZSIC 1841)

businesses

69 (ANZSIC 1842) businesses

ANZSIC 1841 & 1842

Combined data Pfizer (16.5%)

AstraZeneca (10%)

GlaxoSmithKline (10%)

Merck Sharp & Dohme (5%)

Sanofi-Aventis (5%)

Mylan Australia(3.5%)

CSL (3%)

Novartis Australia

Veterinary

Pharmaceutical

and Medicinal

Product

Manufacturing

(1842)


Veterinary drugs, medicines,

medicinal chemicals,

vaccines, serums and otherpharmaceutical products


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13. Cleaning Compound and Toiletry Preparation

Activity

(ANZSIC code)


(market share %)

Cleaning

Compound

Manufacturing

(1851)


Cleaning compounds including

toothpaste, soaps and other

detergents, surface active

agents, polishes and specialty

cleaning preparations.

426 businesses

Colgate-Palmolive (16%)

Unilever Australia (8.5%)

Huntsman Corporation (4%)

Symex (3.5%)

PZ Cussons (3%)

SC Johnson & Son (2%)

Cosmetic and

toiletry

Preparation

Manufacturing

(1852)


Cosmetic and toiletry

preparations including

deodorants, hair products,

make-up, nail polishes,

perfumes, sunscreens.

453 businesses

Unilever (12%)

Colgate-Palmolive (11%)

Julique

Redwin

Aesop

G&M Australia

The Cedel Company

14. Polymer Product Manufacturing

This generally relates to manufacturing of intermediate or end-use plastic products for

consumer goods or for use in construction. These products are often made through

blow and injection moulding or plastic extrusion processes.

Activity

(ANZSIC code)


(market share %)

Polymer Film This includes making: 312 businesses


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Activity

(ANZSIC code)


(market share %)

and Sheet

packagingMaterial

Manufacturing

(1911)

Polymer film or polymer sheet

into packaging materials(plastic bags, packets, food

wrapping, garbage bags,

plastic lamination)

Amcor (22%)

Aperlo Group (16%) Sealed Air Australia (16%)

Innovia Films (3.5%)

Detmark Poly Bags (0.7%)

Vicpac Industries Australia(0.4%)

Rigid and

Semi-Rigid

PolymerProduct

Manufacturing

(1912)


Rigid or semi-rigid polymer

products (plastic badges,

bottles, buckets, clothes pegs,

dinnerware, pipes, furniture,

toilet fixtures, shower stalls,

bathtubs, tubes and rods)

1274 businesses (largest

subsector of plastics)

Pratt Holdings Geminder Holdings

HP Industries

Fletcher Building

MML Holdings

Sekisui Rib Loc Group

Bayer Australia

PolymerFoam Product

Manufacturing

(1913)

This includes making: Polymer foam products (plastic

bicycle safety helmets, cooler

and ice chest, food containers

made from polymeric foam)

Sheet Foam, insulation and

cushioning material

165 businesses Huntsman Corporation (17%)

Huhtamakl Holdings (8.1%)

Joyce Foam (7.5%)

Pacific Brands (6%)

Bridgestone Australia (2.3%)

Sleepyhead Manufacturing(2.0%)

Sleepyhead Manufacturing

(2%)

I.N.C. Corporation (1.2%)

Polyfoam Australia (1.%)

Tyre

Manufacturing

(1914)


tyres from synthetic polymers

and/or natural rubber, tyre

repair materials and inner

tubing for aircrafts and motor

126 businesses

Bridgstone Australia (15%)

Goodyear Tyre and RubberCompany

South Pacific Tyres


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Activity

(ANZSIC code)


(market share %)

vehicles

Retread or rebuild tyremanufacturing

Adhesive

Manufacturing

(1915)


Bonding agents (glues,

adhesives, rubber adhesives)

39 businesses

Momentive Specialty

Chemicals

Paint and

Coatings

Manufacturing

(1916)


Pigments, solvents and bindersinto paints and coatings

Allied paint products (putties,caulking compounds, paint and

varnish removers)

Rubbing compounds

Inks and toners

399 businesses

Duluxgroup (18.5%)

PPG industries (11%)

Wattyl Holdings (11%) Akzo Nobel Coatings (8%)

Cameleon Paints

Haymes Paint

Viponds Paints

Parr Paints

House of Kolor

Ink businesses

DIC Australia (30%) Flint Group (29%)

Toyo Ink Australia

Other

Polymer

Product

Manufacturing

(1919)


Polymer composite products(fibreglass, resilient floor

coverings)

Other products not elsewherestated (garbage bins, gloves,

high density safety equipment,

hoses, hull boat building, motor

vehicle and boat parts, vacuum

cleaner belt.

900 businesses


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Motor Vehicle and Motor Vehicle Part Manufacturing

This generally relates to the making of cars, vans, trucks, buses and their engines,

body, trailers, electrical components and parts. The activities include processes such

as bending, forming, welding, machining, and assembling primarily metals and plasticsinto components or finished vehicles.

Activity

(ANZSIC code)


(market share %)

Motor Vehicle

Manufacturing

(2311)

Construction and

assembly of finished

vehicles and their

engines.Activities including:

Engine manufacturing

Large-size cars

Luxury and all other

cars

Medium-size cars

Small-size and hybridcars

SUVs

Trucks

Heavy Trucks

Utes

Vans and buses

71 Businesses

(IBIS World 2012)

3 major players:

- Toyota MotorCorporation

Australia Limited

(45.3%)

- GM Holden Ltd

(23.7%)

- Ford Motor

Company of

Australia Limited

(18.7%)


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Activity

(ANZSIC code)


(market share %)

Motor Vehicle

Body andTrailer

Manufacturing

(2312)

Manufacture of motor

vehicle bodies,recreational vehicles

such as caravans and

trailers (including boat

trailers).

Includes vehicle

modifications involving

permanent changes tobodywork using existing

engines and chassis

e.g. Fire truck and

Ambulance converting.

Also includes:

Boat trailers

CaravansHorse floats

Motor vehicle

conversion

Stock cratemanufacturing

Trailer manufacturing

Car, truck, bus bodymanufacturing

Camper vans and

motorhomes

Motor vehicle bodies

Motor vehicle trailers

Tent and camper

trailers and caravans

1,168 Businesses

(IBIS World 2012)3 major players:

- Jayco Corporation

Pty Ltd (13.7%)

- MaxiTRANS

Industries (Limited

7.0%)

- FleetwoodCorporation (Limited

5.5%)


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Activity

(ANZSIC code)


(market share %)

Automotive

ElectricalComponent

Manufacturing

(2313)

Includes manufacture of

automotive electricalcomponents such as:

1. Air conditioners

2. Automotive

electrical contents

3. Electric car horns

4. Heaters and

demisters

5. Ignition coils and

spark plugs

6. Lighting products

7. Starter motors and

alternators

8. Windscreen wipers

Firms in this industry do

not manufacture

batteries they fall into

ANZSIC Class 2439.

223 Businesses

(IBIS World 2012)2 major players:

- Robert Bosch

(Australia)

Proprietary Limited

(27.2%)

- DENSO

InternationalAustralia Pty Ltd

12.1%


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Activity

(ANZSIC code)


(market share %)

Other Motor

Vehicle PartsManufacturing

(2319)

Includes manufacture of

non-electricalautomotive

components, such as:

Brakes and parts

Marine engine

conversion

Motor reconditioning

Seats and interiorcomponents

Steering and

suspension parts

Transmission and

parts

Child car restraint

manufacturing

Gearbox

manufacturing

Muffler and radiator

manufacturing

Roof rack

manufacturing

Transmission andclutch manufacturing

Wheel manufacturing

They do not

manufacture engines or

car seats. These

companies may supply

the motor vehicleassemblers or

replacement parts (the

aftermarket).

852 Businesses

(IBIS World 2012)There are No Major

players in this industry

but some players are:

- Arrowcrest Group

Pty Ltd (4.0%)

- Pacifica Group Ltd

(3.1%)- ARB Corporation

(2.5%)


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Other Transport Equipment Manufacturing.

This generally relates to the making of boats, ships, railway and rolling stock vehicles,

planes, gliders, helicopters, motorbikes, scooters and even hovercraft. It is a highlymechanised sector which is known to be innovative and competitive.

This sector is similar to the motor vehicle sector in that the activities include processes

such as bending, forming, welding, machining, and assembling primarily metals and

plastics into components or finished vehicles.

Activity

(ANZSIC

code)


(market share %)

Shipbuilding

and Repair

(2391)

Companies involved in the

Australian Shipbuilding industry

primarily manufacture or repair

vessels of 50 tonnes and over

displacement.

Other activities include:

Dry dock operation

Hull cleaning

Ship repairing

Shipbuilding

Shipwrecking

Submarine component

manufacturing

Submarine construction

Defence-related repair and

maintenance

Defence-related shipbuilding

624 Businesses

(IBIS World 2012)

4 major players:

- BAE Systems

Australia Holdings

Limited 36.8%

- Austal Limited

18.8%

- ASC Pty Limited

16.8%

- Thales Australia

Holdings Pty

Limited 10.7%


41/45

Activity

(ANZSIC

code)


(market share %)

Boatbuildingand Repair

Services

(2392)

This industry comprisescompanies that build or repair

boats of under 50-tonnes

displacement. More simply, the

industry manufactures small to

medium-size boats.


BoatbuildingDinghy manufacturing

Jet boat manufacturing

Sail boat manufacturing

Motorboat building

Yacht constructing

Cuddy or half-cabin cruisersDinghies

Full-cabin cruisers

Open runabouts

Other craft

Repairs

Sailing vessels

Ski or wake boats

1,769 Businesses(IBIS World 2012)

1 major player:

- ACN 102 298 279

Pty Ltd

[Formally known as

Riviera Group Pty

Ltd] (22.0%)


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Activity

(ANZSIC

code)


(market share %)

RailwayRolling Stock

Manufacturing

and Repair

(2393)

Consists of establishments thatmanufacture or repair railway or

tramway locomotives and rolling

stock, such wagons and

passenger carriages.


Railway rolling stock

manufacturingRepair of locomotives and

rolling stock

Tram manufacturing

Coal trucks, hoppers and ore

wagons

Electric and diesel locomotives

Goods wagons and freight cars

Passenger cars

Refurbishment and repairs

Tank cars, tramcars and trolley

cars

Underframes, steel tyres andwheels

118 Businesses(IBIS World 2012)

4 major players:

- Downer EDI Limited

(31.2%)

- UGL Limited

(29.1%)

- BombardierTransportation

Australia Pty Ltd

(7.6%)

- Bradken Limited

(4.1%)


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Activity

(ANZSIC

code)


(market share %)

AircraftManufacturing

and Repair

Services

(2394)

The industry includes businessesthat manufacture aircraft and

aircraft engines and frames used

for civilian and military purposes.

Industry services also include

aircraft maintenance, repair and

overhaul (MRO).

Other activities include:Manufacturing aircraft,

including helicopters and

gliders

Manufacturing guided missiles

Maintenance, repair and

overhaul of aircraft, engines

and avionics

Commercial aircraft, engines,

frames and parts

Light aircraft, engines, frames

and parts

Maintenance, repair andoverhaul

Military aircraft, parts andguided missiles

789 Businesses(IBIS World 2012)

3 major players:

- Boeing Australia

Holdings Pty Ltd

(20.8%)

- Australian

Aerospace Limited(19.9%)

- BAE Systems

Australia Holdings

Limited (16.9%)


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