Dr. Khaled Abdel Ghany

Head of Rapid Prototyping Division 

Activities:

• Upgrading the technical capabilities for the design and manufacturing and innovation of new value-added products – that can access and compete in the global markets in different countries in Egypt, Africa and Arab Countries.
• Electronic Drafting and 3D Modeling
• CAE, Stress Analysis and Simulation
• Rapid Prototyping and Manufacturing using REAL METALS
• 3D Printing and Rapid Manufacturing using Plastic Materials
• Design and Manufacturing of Plastic Molds

• Electronic Drafting and 3D Modeling :

Using the state of the art of CAD software, every product can be 2D drafted and 3D modeled electronically on the computer screen including complicated surfaces and details that can be captured using 3D Scanner. The electronic 3D Models can be sent to CAE software for stress analysis, simulation and design approval, CAM for traditional machining and 3D printing for the rapid manufacturing.
Software Tools:

• EDS Unigraphics NX4,
• AutoDesk AutoCAD
• AutoDesk Inventor
• DelCAM Power Shape
  

• CAE, Stress Analysis and Simulation :

Using CAE software, the 3D modeled products can be studied under simulated working conditions such as static, dynamic and variant mechanical and thermal stresses. From the study results, important decisions can be taken to improve the design and the product added-value such as modifying the materials and weight, increasing wall thickness, modifying holes and fillets, etc. Product life time, durability, performance and human satiety factors can be also predicted from the analysis results.
Software Tools:

• ANSYS 10 (finite element analysis)
  

• Rapid Prototyping and Manufacturing using REAL METALS

3D printing - Rapid Prototyping - Rapid Manufacturing - Free Form Fabrication are all the new names for the technologies that are used to output the electronic model from the computer screen direct into real product - made from real materials - using only one machine.
Our lab has installed m3Linear, the first machine in Africa and the Middle East that builds REAL METAL products that output directly from the computer screen. m3Linear uses laser to melt and micro weld the particles of the layered powders until the complete solid is formed.

• Metallic powder is hereby fully fused layer for layer to produce a 100% component density. A specially developed exposure strategy allows the generation of solid and large-volume components without any deformation. A patented surface post-treatment process directly after the construction process ensures the highest surface quality and hardness. Countless technical refinements such as automatic powder evacuation, a separately developed coating system and a circulating inert gas atmosphere make the M3 linear a machine concept in a class of its own.
  

• The products have density up to100%, very homogeneous microstructure and industrial acceptable surface roughness. Small details and very thin walls up to 1 mm can be built efficiently without problems and near real strength.

Products can be built by any type of metallic powder such as stainless steel, tool steel and alloy steel, etc.
Products can be Metallic products: low productions batches, spare parts, tools, die and mold inserts, medical implants, etc.
Hardware Tools:

• m3Linear (by Concept-laser, Germany)