How 3D printing can improve African manufacturing
CMU-Africa student Mariam Sulleiman addresses manufacturing challenges in Africa by integrating 3D printing, also known as additive manufacturing, into existing infrastructure.
Researchers suggest combining additive manufacturing (AM) with traditional casting methods to help modernize outdated manufacturing practices in Africa, which could make it easier for the continent to adapt to supply chain volatility. AM is a 3D printing technique that enables customization, rapid prototyping, reduced material waste, and cost-effective production of small-batch parts. This research was led by Mariam Sulleiman, a CMU-Africa student studying electrical and computer engineering, and was accepted to the 25th International Conference on Engineering Design (ICED25).
“Most of the available papers on additive manufacturing don’t focus on the African context, so I’m happy that people will have the opportunity to learn more about African manufacturing and how it can contribute globally,” said Sulleiman.
Sand casting is a process where molten metal is poured into a sand mold that defines the final shape of manufactured parts.
The study examines how AM could be applied to sand casting, a process where molten metal is poured into a sand mold that defines the final shape of manufactured parts. Two AM methods are proposed; the first is 3D Sand Printing (3DSP). In 3DSP, the sand mold itself is directly printed and allows for increased casting complexity and quality, reduced weight of finished parts, shorter manufacturing lead times, minimal product and development delays, and reduced inventory needs. The second method is AM investment casting, which involves 3D printing a wax investment pattern that is subsequently covered in a ceramic shell. Both of these methods heavily utilize digital 3D models that provide more flexibility than traditional casting methods. It’s easier and less expensive to change a digital 3D model than to create a new casting mold.
Sulleiman became interested in AM after using it to create a robot in her undergraduate studies.
I’m happy that people will have the opportunity to learn more about African manufacturing and how it can contribute globally.
Mariam Sulleiman, M.S. student, Electrical and Computer Engineering
“We used additive manufacturing to create a robotic crawler that helps survey pipelines for defects like corrosion and dents,” said Sulleiman. “That opened my eyes to the potential of how additive manufacturing could be very useful in an African setting.”
Establishing AM hubs across Africa would help integrate AM-powered casting into existing infrastructure. These hubs would use AM to produce investment casts and sand molds for existing manufacturing supply chains, which could enhance local production capability.
Establishing AM hubs across Africa would help integrate AM-powered casting into existing infrastructure.
The researchers suggest implementing AM-powered casting in agricultural, agro-processing, and automotive manufacturing first, because of the complicated geometry of equipment and machinery in those sectors. AM is good at producing complex parts in small batches, as opposed to mass producing thousands of simple parts. The agricultural and agro-processing sectors contribute 35 percent to Africa’s gross domestic product and employ 70 percent of the population.
“Thinking outside of the box is essential when it comes to design for additive manufacturing,” said Chris McComb, professor of mechanical engineering and coauthor of this research. “It is not a one-size-fits-all solution, but it can be a huge force multiplier when combined with traditional techniques, like casting. This kind of creativity, which Mariam embodies, is essential for the inclusive digital transformation of the continent.”
This kind of creativity, which Mariam embodies, is essential for the inclusive digital transformation of the continent.
Chris McComb, Professor, Mechanical Engineering
Sulleiman enjoyed studying in Pittsburgh through the student exchange program, which gave her the opportunity to work with McComb on this research.
“Working with Professor Chris McComb was a major highlight for me because aside from the weekly meetings with him, I also got to be in the lab and learn about the different interesting projects his Ph.D. students were doing,” explained Sulleiman. “That was one of the motivations for me to apply for Ph.D. programs.”
After she graduates in 2025, Sulleiman plans to pursue a Ph.D. in mechanical engineering.
Other authors of this research include Guha Manogharan, Michael Kay, and Ramin Ahmed.