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 a
platform, 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.

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. A
re-coater mechanism is used to cover the previous layer with the material
enabling the next layer to be scanned.

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

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 steels
Nickel 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 drastically
decrease 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 alloys
Titanium aluminides
Nickel based super alloys
Aluminium
Tool steel
Stainless steel
Hard metals (including Tungsten)
Amorphous metals
Copper
Niobium
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
6

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 (<10 microns), range of layer thickness from
tenths of nanometres to several microns, accurate vector pattern generation with
excellent edge definition and low temperature processing.
An extensive variety of deposition and substrate materials can be used, even
thermo sensitive materials such as epoxies, polymers, proteins and DNA. Some
of the interesting applications of aerosol jet systems include electronic sensors
and touch screen displays, 3D printed electronic devices, solid fuel and solar
cells, electromagnetic interference shielding and surface biofunctionalization of
biomedical devices.

4. SPARK PLASMA SINTERING

The AMCRC currently has a Strategic Project running in SPS with CSIRO.
SPS typically involves lower sintering temperatures and faster heating rates
SPS (Spark Plasma Sintering) is a rapid sintering technique in which mechanical
pressure and electric current are simultaneously applied to produce dense
materials. Compared to conventional methods, SPS typically involves lower
sintering temperatures and faster heating rates. This inhibits grain growth, allows
better control over phase transformations and reduces energy consumption.

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.

Sintering is 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, intuitive
example 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
8

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, fuel
nozzles, 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 a
complete 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 parts
Reverse 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 characterisation
capabilities 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 manufacturing
can 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 added
production 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 intensive
industrial 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 low
efficiency 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 the
production 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.

15

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 computer
recycling 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, resolution
and 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 same
effects 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
16

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 of
material 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), optical
instruments or equipment, or
ophthalmic equipment. Also included
are units mainly engaged in grinding
optical lenses.

Redflex Holdings(VIC) 9.1%

Medical &
Surgical
Equipment
Manufacturing
(2412)

This class consists of units mainly

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

This class consists of units mainly

engaged in manufacturing
navigational, measuring or other
professional and scientific equipment

Agilent (Australia) Pty(VIC)

12.6%
Danaher Australia Holding
Pty Ltd(VIC) 7%

18

Carl Zeiss Vision (VIC) 8.1%

Ellex Medical Lasers(SA)
5.8%

Manufacturing not elsewhere classified such as

Thales Australia(NSW)
(2419)
control or meteorological or surveying 5.7%
equipment or instruments, or
specialised parts for such equipment.

2. Computer and Electronic Equipment Manufacturing

Activity

Description

Major Companies
(market share %)

Computer and
Electronic
Office
Equipment
Manufacturing
(2421)

This class consists of units mainly

engaged in manufacturing
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)

This class consists of units mainly

engaged in manufacturing
electronic and/or studio equipment
for 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%

Other
Electronic
Equipment
Manufacturing
(2429)

This class consists of units mainly

engaged 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%

(ANZSIC code)

19

Gaming machines:
Aristocrat Leisure(NSW)
27.4%
Ainsworth(NSW(13%)

headphones, electronic equipment

or components not elsewhere
classified. Includes gaming
machines

3. Electrical Equipment Manufacturing

Activity

Description

Major Companies
(market share %)

Electric Cable
and Wire
Manufacturing
(2431)

This class consists of units mainly

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 telecommunications
cables 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)

This class consists of units mainly

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)

This class consists of units mainly

engaged in manufacturing
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%

(ANZSIC code)

20

transformers or other electrical

machinery, equipment, supplies or
components not elsewhere
classified.

4. Domestic Appliance Manufacturing

Activity

Description

Major Companies
(market share %)

This class consists of units mainly

engaged in manufacturing
domestic electric, electronic or gas
whiteware appliances. Whiteware
includes domestic cooking,
refrigeration, freezing or washing
appliances. Also included are units
mainly engaged in manufacturing
food waste disposal units or
barbecues

Electrolux (NSW) 21.3%

Rheem Australia(NSW) 16.8%
GWA Group(NSW) 6.2%
Hastie Group(NSW) 6%

(ANZSIC code)

Whiteware
Appliance
Manufacturing
(2441)

5. Pump, Compressor, Heating and Ventilation Equipment Manufacturing

Activity

Description

Major Companies
(market share %)

This class consists of units mainly

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%

(ANZSIC code)

Pump and
Compressor
Manufacturing
(2451)

21

Fixed Space
Heating,
Cooling and
Ventilation
Equipment
(2452)

This class consists of units mainly

engaged in manufacturing
commercial or industrial fixed
space heating, cooling and air
conditioning 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, refrigerated
display 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

Description

Major Companies
(market share %)

Agricultural
Machinery
and
Equipment
Manufacturing
(2461)

This class consists of units mainly

engaged in manufacturing
agricultural machinery or
equipment, tractors for agricultural
purposes (except crawler tractors),
lawn mowers or specialised parts
for 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)

This class consists of units mainly

engaged in manufacturing
construction, earthmoving or
mining machinery and equipment,
or specialised parts for such
equipment. Also included are units

Atlas Copco(NSW) 11.2%

Bradken Limited(NSW) 7.6%
Boart Longyear(SA) 6.5%
Caterpillar(VIC) 3.2%

(ANZSIC code)

22

mainly engaged in manufacturing

crawler tractors and tractors for
construction or earthmoving
purposes.
Machine Tool
and Parts
Manufacturing
(2463)

This class consists of units mainly

engaged in manufacturing
woodworking or metalworking
machinery or equipment, or
specialised parts for such
equipment. Also included are units
mainly engaged in manufacturing
pneumatic 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)

This class consists of units mainly

engaged in manufacturing
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

Description

Major Companies
(market share %)

This class consists of units mainly

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%

(ANZSIC code)

Lifting and
Material
Handling
Equipment
Manufacturing
(2491)

23

such equipment. This class also

includes units mainly engaged in
manufacturing elevators,
escalators or lifts, or in
manufacturing tractors not
elsewhere classified.
Other
Machinery
Equipment
Manufacturing
(2499)

This class consists of units mainly

engaged in manufacturing
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

Description

Major Companies
(market share %)

(ANZSIC code)

Iron and steel Make cast iron or steel products

24

367 businesses:
7 large businesses (~50%)

casting
(2121)

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

forging (e.g. rail lines). The
industrys main products are iron
Iron and steel and steel tubes, pipes, vehicle
forging
parts (doors, frames, exhaust
(2210)
pipe, etc) and railway, machinery
and mining infrastructure.

- Bradken
- Tyco Flow Control
- Castle Harlan Australian
Mezzanine (Intercast &
Forge)
- CMI Industrial (Engineered
Components, Toowoomba
Metal Technologies)
Except big businesses, firms tend
- Crane Group (Crevet)
to operate in either casting or
- Ajax Foundry
forging (not both).
- Beverley Industries
360 small businesses (31%)
OneSteel (19%)
83 businesses:
Make castings and forgings
primarily of aluminium, and also 5 medium business (~50%)
- Arrowcrest (John Shearer,
copper, zinc and lead. The
ROH Wheels)
industrys main products are
- Mett Diecasting
aluminium castings for the
- Melbourne Gravity
automotive industry (e.g. wheels, - Lenlok
transmission, gear boxes) and
- Mullins Wheels
78 small business (~50%)
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).

25

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

Description

Companies
(ANZSIC code)
(market share %)
Steel pipe and Make seamless or welded steel 235 businesses (46%) e.g.
- Hills Holding (Orrcon)
tube
or ferrous pipes and tubes using
-Stainless Tube Mills
manufacturing methods other than casting or
OneSteel (54%) not eligible
forging (e.g. cold drawn pipes).
(2122)
(STP)
56 businesses:
Aluminium
Make aluminium sheets, rods,
2 big businesses (36%)
rolling,
bars, pipes, plates, tubes, wire,
- Capral
drawing,
powder, flakes and foil. This is
- Alcoa Australia Rolled
extruding
done by hot or cold rolling,
Products
(2142)
drawing or extruding. The
Other businesses:
industrys main products are
- Ullrich Aluminium
aluminium sheets or shapes
- GJames Extrusion Co
- Almax Aluminium
used in transport, construction,
- Independent Extrusions (InEx)
packaging or household items,
- Extrusions Australia
as well as aluminium rods and
- Extrusions Profile Australia
extruded sections (e.g.
- Aluminium Shapes
construction bars, wheels).
(AluShapes)
Other basic

Rolling, drawing or extruding

26

129 businesses:

non-ferrous
metal product
manufacturing
(2149)

11.

1 big business (45%)

non-ferrous metals, other than
- MML (MM Kembla)
aluminium, into primary shapes.
Industrys major products are of Others, e.g. Crane Group (4%)
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).

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

Description

Companies
(market share %)

(ANZSIC code)

~2,000 businesses:
Structural
This includes making:
Bigger businesses include:
metal product structural steel components
- Capral
(beams, joists, bars, steel
manufacturing
- JELD-WEN
wire/mesh) for incorporation
(222)
- Boral
in buildings & other
- Alesco
structures.
- Valmont (Webforge)
pre-fabricated metal buildings
- Airport Doors
(bus shelters, carports,
- Permasteelisa
garages, sheds, etc)
- Gliderol
architectural aluminium
- Mirage Industries
products (doors, railings,
- Acrow Formwork & Scaffolding
gates, window frames,
- Centurion Garage Doors
shower screen frames,
- Modular Metals
garage doors, shutters, etc)
27

 metal roofing and guttering

architectural steel, wrought
iron or other metal products
(staircases, balconies,
window frames, decks etc)

OneSteel and Bluescope Steel

are not eligible (STP)

Not included: assembly of

complete pipelines or steel
towers (construction)
Metal
This includes making:
container
heavy gauge containers
manufacturing
(metal boilers, superheaters,
(223)
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, shipping
barrels & drums)
Sheet metal
This includes making:
product
a large range of products
manufacturing
from sheet metal (air ducts,
(224)
guttering, bottle lids, can lids,
sanitary ware products, bins
& hoppers, vehicle number
plates)

Other
fabricated
metal product

This includes making:

spring or wire products for
use in construction, mining,
28

>100 businesses:
Bigger businesses include:
- Amcor
- Pratt
- Impress Australasia
- National Can Industries

1,775 businesses, many small

Bigger businesses (18%)
- GWA Group
- Hills Holding
- Amcor
- National Can Industries
Bluescope Steel (12%) not
eligible (STP)

>6,000 businesses
Bigger businesses include:
- ACME Operations
- Noza

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 and
machinery, 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)
29

 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

Description

Companies

(ANZSIC code)

Natural
This includes making:
Products made solely from
Rubber
natural rubber (bath mats,
Product
condoms, conveyor belts,
Manufacturing
dummys, hoses, hot water
(1920)
bottle, mattress protector,
rubber balloons, sponges,
30

177 businesses
Ludowici
Fenner Dunlop
Vulcanite
Nylex

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

Description

Companies
(ANZSIC code)
(market share %)
Human
This includes making:
318 (ANZSIC 1841)
Pharmaceutical Pharmaceutical and medicinal businesses
products for human use from 69 (ANZSIC 1842) businesses
and Medicinal
both natural (plants) and
Product
synthetic sources (chemicals).
Manufacturing
ANZSIC 1841 & 1842
These include antibiotics,
(1841)
Combined data
vitamins, vaccines etc.
Pfizer (16.5%)
Diagnostic substances for
AstraZeneca (10%)
antibodies, antigens and
GlaxoSmithKline (10%)
chemical diagnostic testing
Merck Sharp & Dohme (5%)
agents
Sanofi-Aventis (5%)
Veterinary
This includes making:
Mylan Australia(3.5%)
Pharmaceutical Veterinary drugs, medicines,
CSL (3%)
medicinal chemicals,
and Medicinal
Novartis Australia
vaccines,
serums
and
other
Product
pharmaceutical products
Manufacturing
(1842)

31

13.

Cleaning Compound and Toiletry Preparation

Activity

Description

Companies
(market share %)

(ANZSIC code)

Cleaning
This includes making:
Cleaning compounds including
Compound
toothpaste, soaps and other
Manufacturing
detergents, surface active
(1851)
agents, polishes and specialty
cleaning preparations.
Cosmetic and This includes making:
Cosmetic and toiletry
toiletry
preparations including
Preparation
deodorants, hair products,
Manufacturing
make-up, nail polishes,
(1852)
perfumes, sunscreens.

14.

426 businesses
Colgate-Palmolive (16%)
Unilever Australia (8.5%)
Huntsman Corporation (4%)
Symex (3.5%)
PZ Cussons (3%)
SC Johnson & Son (2%)
453 businesses
Unilever (12%)
Colgate-Palmolive (11%)
Julique
Redwin
Aesop
G&M Australia
The Cedel Company

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

Description

Companies
(market share %)
312 businesses

(ANZSIC code)

Polymer Film

This includes making:

32

Activity

Description

(ANZSIC code)

Polymer film or polymer sheet

and Sheet
into packaging materials
packaging
(plastic bags, packets, food
Material
wrapping, garbage bags,
Manufacturing
plastic lamination)
(1911)
Rigid and
This includes making:
Rigid or semi-rigid polymer
Semi-Rigid
products (plastic badges,
Polymer
bottles, buckets, clothes pegs,
Product
dinnerware, pipes, furniture,
Manufacturing
toilet fixtures, shower stalls,
(1912)
bathtubs, tubes and rods)

Polymer
This includes making:
Foam Product Polymer foam products (plastic
bicycle safety helmets, cooler
Manufacturing
and ice chest, food containers
(1913)
made from polymeric foam)
Sheet Foam, insulation and
cushioning material

Tyre
This includes making:
Manufacturing tyres from synthetic polymers
and/or natural rubber, tyre
(1914)
repair materials and inner
tubing for aircrafts and motor
33

Companies
(market share %)
Amcor (22%)
Aperlo Group (16%)
Sealed Air Australia (16%)
Innovia Films (3.5%)
Detmark Poly Bags (0.7%)
Vicpac Industries Australia
(0.4%)
1274 businesses (largest
subsector of plastics)
Pratt Holdings
Geminder Holdings
HP Industries
Fletcher Building
MML Holdings
Sekisui Rib Loc Group
Bayer Australia
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.%)
126 businesses
Bridgstone Australia (15%)
Goodyear Tyre and Rubber
Company
South Pacific Tyres

Activity

Description

(ANZSIC code)

Companies
(market share %)

vehicles
Retread or rebuild tyre
manufacturing
Adhesive
This includes making:
Manufacturing Bonding agents (glues,
adhesives, rubber adhesives)
(1915)

39 businesses
Momentive Specialty
Chemicals

Paint and
This includes making:
Pigments, solvents and binders
Coatings
into paints and coatings
Manufacturing
Allied paint products (putties,
(1916)
caulking compounds, paint and
varnish removers)
Rubbing compounds
Inks and toners

Other
This includes making:
Polymer composite products
Polymer
(fibreglass, resilient floor
Product
coverings)
Manufacturing
Other products not elsewhere
(1919)
stated (garbage bins, gloves,
high density safety equipment,
hoses, hull boat building, motor
vehicle and boat parts, vacuum
cleaner belt.

34

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

900 businesses

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 plastics
into components or finished vehicles.
Description
Activity
(ANZSIC code)

Companies
(market share %)

Motor Vehicle
Manufacturing
(2311)

71 Businesses
(IBIS World 2012)

Construction and
assembly of finished
vehicles and their
engines.
Activities including:

3 major players:

Engine manufacturing
Large-size cars

- Toyota Motor
Corporation
Australia Limited
(45.3%)
- GM Holden Ltd
(23.7%)

Luxury and all other

cars

- Ford Motor
Company of
Australia Limited
(18.7%)

Medium-size cars
Small-size and hybrid
cars
SUVs
Trucks
Heavy Trucks
Utes
Vans and buses

35

Activity
(ANZSIC code)
Motor Vehicle
Body and
Trailer
Manufacturing
(2312)

Description

Companies
(market share %)

Manufacture of motor
1,168 Businesses
vehicle bodies,
(IBIS World 2012)
recreational vehicles
3 major players:
such as caravans and
- Jayco Corporation
trailers (including boat
Pty Ltd (13.7%)
trailers).
- MaxiTRANS
Includes vehicle
Industries (Limited
modifications involving
7.0%)
permanent changes to
- Fleetwood
bodywork using existing
Corporation (Limited
engines and chassis
5.5%)
e.g. Fire truck and
Ambulance converting.
Also includes:
Boat trailers
Caravans
Horse floats
Motor vehicle
conversion
Stock crate
manufacturing
Trailer manufacturing
Car, truck, bus body
manufacturing
Camper vans and
motorhomes
Motor vehicle bodies
Motor vehicle trailers
Tent and camper
trailers and caravans

36

Activity
(ANZSIC code)
Automotive
Electrical
Component
Manufacturing
(2313)

Description

Companies
(market share %)

Includes manufacture of 223 Businesses

automotive electrical
(IBIS World 2012)
components such as:
2 major players:
1. Air conditioners
- Robert Bosch
(Australia)
Proprietary Limited
(27.2%)

2. Automotive
electrical contents
3. Electric car horns

- DENSO
International
Australia Pty Ltd
12.1%

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.

37

Activity
(ANZSIC code)
Other Motor
Vehicle Parts
Manufacturing
(2319)

Description

Companies
(market share %)

Includes manufacture of 852 Businesses

non-electrical
(IBIS World 2012)
automotive
There are No Major
components, such as:
players in this industry
but some players are:
Brakes and parts
Marine engine
conversion

- Arrowcrest Group
Pty Ltd (4.0%)

Motor reconditioning

- Pacifica Group Ltd

(3.1%)

Seats and interior

components
Steering and
suspension parts
Transmission and
parts
Child car restraint
manufacturing
Gearbox
manufacturing
Muffler and radiator
manufacturing
Roof rack
manufacturing
Transmission and
clutch manufacturing
Wheel manufacturing
They do not
manufacture engines or
car seats. These
companies may supply
the motor vehicle
38
assemblers or
replacement parts (the
aftermarket).

- ARB Corporation
(2.5%)

39

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 highly
mechanised 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)
Shipbuilding
and Repair
(2391)

Description

Companies
(market share %)

Companies involved in the

Australian Shipbuilding industry
primarily manufacture or repair
vessels of 50 tonnes and over
displacement.
Other activities include:

624 Businesses
(IBIS World 2012)

Dry dock operation

4 major players:
- BAE Systems
Australia Holdings
Limited 36.8%
- Austal Limited
18.8%

Hull cleaning

- ASC Pty Limited

16.8%

Ship repairing
Shipbuilding

- Thales Australia
Holdings Pty
Limited 10.7%

Shipwrecking
Submarine component
manufacturing
Submarine construction
Defence-related repair and
maintenance
Defence-related shipbuilding

40

Activity
(ANZSIC
code)

Description

Companies
(market share %)

Boatbuilding
and Repair
Services
(2392)

This industry comprises

companies that build or repair
boats of under 50-tonnes
displacement. More simply, the
industry manufactures small to
medium-size boats.
Other activities include:

1,769 Businesses
(IBIS World 2012)

Boatbuilding
Dinghy manufacturing
Jet boat manufacturing
Sail boat manufacturing
Motorboat building
Yacht constructing
Cuddy or half-cabin cruisers
Dinghies
Full-cabin cruisers
Open runabouts
Other craft
Repairs
Sailing vessels
Ski or wake boats

41

1 major player:
- ACN 102 298 279
Pty Ltd
[Formally known as
Riviera Group Pty
Ltd] (22.0%)

Activity
(ANZSIC
code)

Description

Companies
(market share %)

Railway
Rolling Stock
Manufacturing
and Repair
(2393)

Consists of establishments that

manufacture or repair railway or
tramway locomotives and rolling
stock, such wagons and
passenger carriages.
Other activities include:

118 Businesses
(IBIS World 2012)

Railway rolling stock

manufacturing

4 major players:
- Downer EDI Limited
(31.2%)
- UGL Limited
(29.1%)

Tram manufacturing

- Bombardier
Transportation
Australia Pty Ltd
(7.6%)

Coal trucks, hoppers and ore

wagons

- Bradken Limited
(4.1%)

Repair of locomotives and

rolling stock

Electric and diesel locomotives

Goods wagons and freight cars
Passenger cars
Refurbishment and repairs
Tank cars, tramcars and trolley
cars
Underframes, steel tyres and
wheels

42

Activity
(ANZSIC
code)

Description

Companies
(market share %)

Aircraft
Manufacturing
and Repair
Services
(2394)

The industry includes businesses 789 Businesses

that manufacture aircraft and
(IBIS World 2012)
aircraft engines and frames used 3 major players:
for civilian and military purposes.
- Boeing Australia
Industry services also include
Holdings Pty Ltd
aircraft maintenance, repair and
(20.8%)
overhaul (MRO).
- Australian
Other activities include:
Aerospace Limited
(19.9%)
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 and
overhaul
Military aircraft, parts and
guided missiles

43

- BAE Systems
Australia Holdings
Limited (16.9%)

44

45