HANADI SALEM
PROFESSOR OF MATERIALS AND MANUFACTURING
DEPARTMENT OF MECHANICAL ENGINEERING

Working at the cutting edge of a new manufacturing technology

The Inspiration

Manufacturing is undergoing a massive shift. A technology called additive manufacturing, or 3D printing, is revolutionizing the industry, from motor vehicles and consumer products to medicine, the military, gas and oil, and aerospace. We’re seeing breakthroughs every day in fields such as robotics, biomedical engineering, machine learning, architecture and so many more. At AUC, we’re establishing an Additive Manufacturing Centennial Lab. We expect it to be the local and regional pioneer in additive manufacturing research, development and benchmarking. We’ll prepare new generations of scientists and engineers to work with this essential technology. And we’ll develop and share our processes and resources.

Metal additive manufacturing is one of the fastest growing areas in the 3D printing industry, which is predicted to have an economic impact of $40 billion by 2027.

IDTechEx

The Process

Members of our team meet regularly to make plans, brainstorm new ideas and solve problems. At the completion of a project, we submit a written report and give a presentation, which leads either to refinement or approval. We also share our work at major conferences. The projects are diverse, from jet engine parts and racecar spindles to artistic statues. We build net-shaped metal parts and components. What we all share is a commitment to using additive manufacturing in ways that will benefit the industry, environment and society.

The IMPACT

Revolutionary technological advances push the boundaries of progress — economically, socially and environmentally. Additive manufacturing not only allows for efficient use of materials and production at a relatively lower cost than traditional manufacturing, but also reduces complex assembly efforts and increases design flexibility. By embracing the full potential of additive manufacturing and integrating it into traditional manufacturing and product development processes, we’ll see new applications scaling to almost every industry. Companies can limit outsourcing to third parties by developing concepts in-house. They can also create an advantage over competitors by shortening their product development cycle. Last but not least, additive manufacturing is a green process, with minimal waste and reduced emissions. This is progress for everyone. Our additive manufacturing facility offers a unique proposal: the freedom to create more, to inspire innovation and to better society.

The Next Steps

We recently received funding for establishing an integrated metal additive manufacturing robotic system — the first locally and regionally. We’re getting ready to launch our Additive Manufacturing Centennial Lab, which will be a leading facility for exploring new adaptations of additive manufacturing. That’s just a small sample of the work ahead. Both Egypt and AUC have a strong entrepreneurial culture, so there’s always something new.

The Future

AUC is positioned to be a global leader in this field. Our faculty members have expertise in it all — from reverse engineering, process design, modeling and simulation to structural characterization. Our students are highly trained in the field. Our facilities are state-of-the-art. And the University is committed not simply to conducting research, but also to raising awareness and transferring the technology to the local and regional industries where it can have the greatest benefit.