Manufacturing Matters 2021 October - Issue 4

October 2021 | Issue 4 A publication of the Singapore Institute of Manufacturing Technology PAGE | 1

A Note From..... Indeed, it has been a rewarding co- innovation journey with ST Engineering Aerospace to drive the proof of concept of lightweight manufacturing process for aviation demonstrators in the last three years. Together with STEA and coupled with our strong optimisation expertise, the teams have fabricated demonstrators using additive manufacturing technology to achieve remarkable weight savings. The demonstrators were also featured in Global Air Shows in Singapore and Paris 2020. The teams have collaborated closely to overcome challenges in re-designing aluminium tray table arm with Mg alloy for liquid forging technology, while continuing to push forward to achieve 33% weight reduction for Mg arm with AI tip. We have successfully developed shape/topology optimisation methods including the original dual material design option. This is a breakthrough which has further inspired multi-material optimisation and lattice design for additive manufacturing. Through this collaboration journey with STEA, more research topics relating to the additive manufacturing domain have been identified, further enhancing SIMTech’s partnership with STEA. I am grateful to have been part of this collaboration and co-innovation journey with STEA Dr Wang Chen, Scientist, Design and Simulation Team, Polymer Technology Group, SIMTech PAGE | 2

Welcome to Manufacturing Matters 4 - 5Feature Research 6 Spotlight Lightweight Structures and Functional Coatings Identifying Surface Defects or for Aviation Products and Applications Dimensional Deviation on 3D Printed Surfaces 7Innovation 8Precision Matters Matters Co-Innovating with Local Food Trays Disinfection Startup to Build a Healthier Cabinet with Ultraviolet-C and Sustainable Future (UV-C) LED Technologies 9Productivity Skills 10 Matters Matters SGUS for Advanced Workflow Automation in Construction Industry Instrumentation and Quality 11Customer Control through Digitalisation Story CLF 2022 12 - I4.0 and Creating a Positive R&D Beyond Learning Culture Call for Papers Industry 13 14Upcoming Assist Activities PAGE | 3

Feature Lightweight Structures and Functional Coatings for Aviation Products and Applications Developing end-to-end lightweight manufacturing solutions ST Engineering Aerospace (STEA) is the world’s largest commercial airframe Maintenance, Repair, and Overhaul (MRO) provider with global facilities network including America, Asia, and Europe. Besides airframes, STEA provides a comprehensive suite of MRO services in component and engine, aviation materials, and asset management as well as aircraft interior solutions. STEA’s customer base spans from leading global airlines to airfreight, and to military operators. As competition intensifies for faster and more cost effective manufacturing processing solutions to manage prototyping and low volume production, STEA started exploring new manufacturing technologies and growth areas to maintain its standing as a key node in the global aerospace MRO value chain. STEA’s strategy is to develop and implement advanced end-to-end manufacturing solutions to produce high value, lightweight components for the aerospace industry. To support this strategy, the A*STAR’s Science and Engineering Research Council (SERC) co-funded a research collaboration between STEA and a multi-disciplinary team from A*STAR SIMTech from 2017 – 2021. This collaboration aimed to establish interlinked novel design, processing and coating technologies focusing on the development of lightweight structures and functional coatings for aviation products and applications. Based on STEA’s focus to develop productive and cost effective manufacturing processes, suitable aviation demonstrators with generally high buy-to-fly ratio and product requirements were identified to illustrate the desired outcomes. The project team achieved tangible end-to-end solutions based on respective processes of additive manufacturing, liquid forging and composite forming, along with tailored process-specific design, suitable material selection, optimised processing conditions, and customised coating solutions. PAGE | 4

Material selection options included Demonstrator-specific business cases were studied lightweight metallic alloys (Al-, Mg-, and based on the benchmark against respective original Ti-based), structural flame-retardant components. In addition to the experimental thermoplastic polymers, carbon fibre demonstrator validation, SIMTech delivered the reinforced composites and sandwich technical database developed during the project, structures, as well as hybrid combinations outlined technology challenges, and recommended thereof. Process-specific material property Singapore-based companies for commercial scale- databases suitable for design and up opportunities. The project has established the optimisation were established as part foundation for a long-lasting R&D relationship of the project. Tailored state-of-the-art between STEA and SIMTech, which has recently numerical design optimisation strategies resulted in securing further funding opportunities played an integral role for lightweight in key areas of end-to-end additive manufacturing design, enabling significant weight savings solutions, and to complete the commercial translation during the redesign stage. of these additive manufacturing technologies to the aerospace industry. Figure 1 shows examples of demonstrators manufactured and tested during the To be the first in this region to deliver the first EASA project. certified additive manufactured components, using both metallic and polymeric materials for aviation Figure 1(a) shows a fuel line holder applications, we need to invest in our people and redesigned for additive manufacturing ecosystem. Forward looking proof of concept R&D and printed from AlSi10Mg via selective collaboration with SIMTech, has earned us insights and laser melting, achieving significant understanding of various manufacturing technologies, weight savings of >30% compared to the and has created good references and foundation for original cast design. These lightweight commercialisation. The experience gained and the team demonstrators highlighting advances in rapport built through this collaboration has furthered Additive Manufacturing technologies were our collaboration. We expect that with this multi-year showcased as part of recent global airshow R&D collaboration with SIMTech it will help to move us exhibits in Paris and Singapore. ahead of the curve; and with SIMTech’s high productivity solutions in Additive Manufacturing that underpin Figure 1(b) shows a hybrid material solution appealing business cases, the collaboration outcome for a tray table arm, processed via liquid can be translated into commercial applications, which in forging technology developed by SIMTech. turns boosts Singapore AM ecosystem The hybrid AZ91-Ca / Al2024 design solution allows for > 35% weight saving compared Dr Zheng Guoying, Vice President, AMDC, I&CI, to the original machined design. Commercial Aerospace, ST Engineering Figure 1(c) shows a high stiffness/strength (a) (b) carbon fibre reinforced sandwich composite meal table product, fabricated as a one- (c) (d) step forming solution inclusive of insert placement with comparable processing Figure 1: Demonstrator solutions with viable business case studies for costs for medium-volume production. technology commercialisation Lastly, Figure 1(d) shows the interior multi- For enquiries, please contact functional coating formulations suitable Dr Ng Sum Huan Gary, Acting Director, SEAC for high polymer substrate versatility, Email: [email protected] customised for hydrophobicity, scratch Web: www.a-star.edu.sg/SIMTech/SEAC resistance, antimicrobial resistance, and UV blocking requirements via single layer coating. Scan for more information PAGE | 5 on Sustainability & Emerging Applications Centre

Research Highlight Identifying Surface Defects or Dimensional Deviation on 3D Printed Surfaces A point cloud-based online monitoring method assisted by machine learning One of the challenges with a rapid and accurate sensor Being developed for LAAM, 3D printing processes may scans the surface of a printed the proposed technology be the lack of robustness and object to obtain height data. can also be used to monitor repeatability, especially when The multimodal software the surface conditions of used to fabricate large metal automatically processes this other printed materials. parts. Thermal stress, localised 3D spatial data into simple overheating, and inconsistent statistics used by machine This framework can be easily machine are among the learning models, to isolate adapted for other processes by factors that make 3D printing and identify potential surface developing new sets of training prone to surface defects or defects. The proposed rapid data. The ultimate goal is to dimensional deviation. This defect identification method make LAAM technology smart can be detrimental to the final has been implemented in the and fully automatic, with self- piece if it is not detected early. robot-based laser-aided additive learning and self-rectification Vision-based surface topography manufacturing (LAAM) system capabilities. This will enhance measurement methods with developed by SIMTech JMG. This the printing quality and cameras and computer vision unique metal 3D printing process maximise productivity with algorithms were traditionally is ideal for manufacturing of minimal human intervention. used to digitally reconstruct large-format metal components. The next step of the research is the 3D surface. However, the to develop a way for the machine surface reconstruction process Researchers have trained to perform intelligent decision can be computationally heavy classifier algorithms to identify making and adaptive process and limited in terms of precision three main classes of surface planning and execution after and resolution. non-conformance — bulge, dent, errors are detected. wavy defects and defect-free The Joining & Machining Group surfaces using 73 LAAM-printed For more information, please contact (JMG) at SIMTech has developed samples of varying sizes and Dr Yao Xiling, Scientist, Joining & a method that can detect shapes. Compared to surface Machining Group at yao_xiling@ surface defects efficiently. monitoring techniques, this SIMTech.a-star.edu.sg In-house designed software new method rapidly detects and that simultaneously executes classifies defects even when multiple point cloud processing there are multiple defect regions functions and integrates the present in the same layer. data into machine learning models. In this new system, PAGE | 6

Innovation Matters Co-Innovating with Local Startup to Build a Healthier and Sustainable Future Combating plastic waste problem with edible cutlery Co-founded by Anna Lam, Crunch Cutlery became of thinking outside the box and maintaining the first startup in Southeast Asia to tackle issues the essence of organic and wellness, the new associated with plastic waste, whilst at the same design has also successfully incorporated the time providing nutritional benefits to consumers elements of being fun. – all in a single product. Made up of flaxseed, chia seeds and whole wheat, the edible cutlery The team at Innovation Factory@SIMTech ensures gives a boost of Omega 3, Vitamin B3, lignans and that every aspect of a product development cycle fibre; and acts as a substitute to plastic utensil is well managed, focuses on the needs of all its in which Singaporeans throw away 500 million members’ project aspirations, and shortening units every year. their journey from idea conceptualisation to product commercialisation. Having found early success, Crunch Cutlery identified the need for further upscaling of their Our multidisciplinary teams identify and focus product in the open market, and a collaboration on what is most important for strategy and between Crunch Cutlery and Innovation Factory product development. We help companies @ SIMTech was formed to re-engineer the outlook discover the value of human centered innovation and design of the edible cutlery. by using Design Thinking techniques, co-creating with them to solve their problems, and develop Led by product designer Audrey Ng of Innovation products in shorter times, while achieving high Factory@SIMTech, the initial prototype was based quality at lower cost. on the concept sketching of yin and yang. After gathering and studying users’ feedback, a second For enquiries, please contact design with a more ergonomic approach was Mr Rayner Ng, Deputy Director, IF created. Whilst keeping to Crunch Cutlery’s values Email: [email protected] Website: www.a-star.edu.sg/SIMTech/ The yin-yang symbol, which represents balance Innovation-Factory and harmony, is the inspiration for our Crunch Cutlery design. Through our product, we hope to encourage better nutrition and sustainability practices in our everyday lives Ms Anna Lam, Co-Founder, Crunch Cutlery Scan for more information on Innovation Factory@SIMTech PAGE | 7

Precision Matters Food Trays Disinfection Cabinet with Ultraviolet-C (UV-C) LED Technologies Dine out with assurance during the pandemic COVID-19 has severely impacted hygiene standards on our food In February 2021, Chemikalie the Food and Beverage (“F&B”) trays, the hygiene management deployed their UV-C food Sector. There is consumer team find it a challenge to keep tray disinfection cabinet at a apprehension around the risks trays clean. With the COVID-19 local hawker centre. With the of COVID-19 transmission and pandemic, there was high deployment of this disinfection increased pressure to maintain demands for turn-key hygiene cabinet, cleaners were able to the level of hygiene for high management systems that are do a quick wipe down and insert touch point items such as safe and effective for food trays. the trays into the tray carrier for food trays. Chemikalie Pte Ltd disinfection. This cabinet can (“Chemikalie”) is a scientific In this project, SIMTech provided carry out disinfection of up to instruments and laboratory design to assembly solutions, 36 food trays with an effective product provider that engaged and deployed pilot trial at 5-minute disinfection cycle. With SIMTech in the development of of public space in a short span the UV-C food tray disinfection a high-efficacy UV-C disinfection of 3 months. The UV-C light cabinet being the first of its cabinet to mitigate the public’s engine deployed in the food tray kind using LED technology, concerns in the F&B sector. cabinet leveraged on thermal this development supported management of LED know-how. Chemikalie in capturing new Having interviewed some of the Through collaborating with stream of revenue through members from the Hawkers’ biological test laboratories, the community development as an Association, we learned that UV-C light engine’s disinfection alternate but effective source food trays are one of the efficacy had been validated of disinfection. toughest to implement hygiene to inactivate 99.9% of Human management. With strict NEA Coronavirus in less than 2 mins. guidelines to maintain high Due to the current pandemic and public concern on the hygiene For enquiries, please contact issues of high touch point of food trays, Chemikalie developed a Mr Tan Chee Tat, Director, PE COI UV-C Cabinet in collaboration with SIMTech. The collaboration Email: [email protected] provided validation that the UV-C LEDs in our food tray disinfection Web: www.a-star.edu.sg/SIMTech-PECOI cabinet is reliable and efficient against bacteria and viruses within a short span of 5 minutes. This will greatly address the hygiene issues arising from food waste on trays, free up labour, and save water from manual cleaning and washing of individual tray. We look forward to future development of UV-C products with SIMTech Scan for more information on Precision Engineering Ms Gene Tan, Director, Chemikalie Pte Ltd Centre of Innovation PAGE | 8

Productivity Matters Workflow Automation in Construction Industry Build your foundation for digital transformation The Workflow Automation one of the M&E contractors, Figure 1: ePTW Application Review solution, wfMOBILE™, is an Puretech Engineering Pte Ltd, affordable, and an intelligent to digitalise their Permit-to- workflow design, forms design, and mobile-enabled generic work (PTW) processes using participate in hands-on sessions workflow generator with the SIMTech Work f low Mobile to create mobile workflows. following capabilities: te chnolog y. • No programming required Puretech Engineering Pte The course fee is $1,600 before to enable mobile workflow Ltd has 25 years history GST. Singapore citizens, PRs and of providing Mechanical & employee from local SMEs will • Business rules, Electrical Engineering specialty enjoy up to 90% funding support. configurable database, services, and it is a reputable We look forward to your active user interfaces are main contractor amongst participation in our upcoming defined using Excel property owners and public training programme to kickstart templates sector agencies. Puretech your business process workflow has BCA Grade L6 for ME05 digitalisation • Supports Android, iOS and & ME11 and achieved ISO Web clients 9001, 14001, 27001 & 45001 Figure 2: ePTW in wfMOBILE App certifications. • Runs on cloud or in-house For enquiries, please contact servers With the creation of electronic Mr Rick Yeo, Director, MPTC PTWs, the company has Email: [email protected] wfMOBILE™ has been adopted managed to reduce approval Web: www.a-star.edu.sg/SIMTech-MPTC in many industries including cycle time by 50%, to eliminate built environment, healthcare, paper storage for PTW forms, Scan for more information on manufacturing, services, etc. and to improve productivity in Manufacturing Productivity Below are some examples of preparation for audit reviews. Technology Centre the applications created using of wfMOBILE™. Rollout of “Digitalisation of PAGE | 9 Business Process Workflow” • Order Management Workflow SSG course • Permit-to-Work Workflow We are glad to announce that • Delivery Workflow SIMTech will be launching • Ser vice Tracking a 2-day SSG-funded course • Refiner y Turnaround “Digitisation of Business Process Workflow” in During the COVID-19 pandemic November 2021. Participants period, the construction industry will learn the fundamentals of was looking at ways to reduce paper handling transactions and SIMTech collaborated with The wfMOBILE ePTW helps to improve our productivity, effectiveness & security in managing the PTWs, and meets our ISO objective of Digitalisation & Go Green initiative. Our team is able to configure our own ePTWs from the templates given for all of our projects. I also believe we can implement much more workflows with this wfMOBILE App Mr P.Kannan, Deputy Project Director, Puretech Engineering Pte Ltd

Skills Matters SGUS for Advanced Instrumentation and Quality Control through Digitalisation Reskilling the manufacturing workforce In the new era of manufacturing, addition to the lecture modules • Participants will gain hands-on digitalisation is a significant and laboratory practices, the experience with cutting-edge enabler for improving and program will link the training inspection technologies like as upgrading quality control. contents with actual industrial machine vision, 3D scanning, Measurement and inspection demands. robotic microscopy, and Al- procedures can become more assisted fault identification. intelligent and autonomous by This program will provide digitalising instrumentation intensive hands-on practice • Characterisation Methods and systems. This SGUS course will instruction on the fundamental Analyses - Participants will provide trainees with the skills of common measurement gain hands-on expertise with fundamentals of advanced techniques, characterisation digitised characterisation instrumentation for quality methods, and data analysis as instruments such as control, as well as on how to use application to advanced programmable dimensional digital technologies like computer- manufacturing. The module is measurement, surface aided design, simulation, digital divided into 26 sessions (for a total characterisation, digital 2D/3D instrumentation, and data analysis of 80 hours) and will provide microscopy, and optical to construct measurement and participants with the chance to parameter quantification, inspection solutions. study and operate measurement/ which are used for quality inspection equipment and verification. Partnering with Skillsfuture analytical instruments in A*STAR Singapore (SSG), SIMTech is now laboratories to reinforce their • Data Processing and Analysis - offering the Advanced knowledge gained from the Participants will be guided Instrumentation and Quality technical skill modules. through the collection and Control through Digitalisation analysis of data from starting from July 2021. This The training sessions will be inspection systems. Image course features laboratory hosted by A*STAR domain quality analysis, feature exercises to help participants specialists from the Singapore recognition, and defect better comprehend current trends Institute of Manufacturing detection will be among the and become familiar with the Technology (SlMTech), Advanced analytical tasks. most up-to-date quality control Remanufacturing and Technology methods. Centre (ARTC), and National For enquiries, please contact: Metrology Centre (NMC) providing Mr Tom Chua, Assistant Industry Development Projects will be prepared based on the participants with hands-on Manager, Knowledge Transfer Office real use cases and mentored by work in these three categories: Email: [email protected] A*STAR domain experts, in Web: www.a-star.edu.sg/SIMTech/KTO PAGE | 10

Customer Story T-Up is a joint initiative by A*STAR and Enterprise Singapore to help local SMEs through the secondment of R&D talents from A*STAR’s research institutes. Creating a Positive R&D Learning Culture JM Vistec (JMV) is a local SME specialised Figure 2: Supervision of university student in machine and robot vision, which offers a full suite of vision components and T-Up helps to create a positive R&D custom build solutions for its clients learning environment and to accelerate by continual innovation in product the time to market development. SIMTech staff, Mr Shen Jian, was seconded to JMV as part of the A*STAR Mr Eugene, Managing Director, JM Vistec T-UP Programme. Shen Jian also played a key role in mentoring JMV’s new R&D recruits – students from Singapore Institute of Technology (SIT-T- UP Partnership Programme), Nanyang and Temasek Poly (Figure 2.). By working closely with Shen Jian, the students were imbued with R&D experience and JMV’s corporate culture, thus creating a positive learning journey for them. Figure 1: 3D fringe projection scanner for 3D Shen Jian started by upgrading JMV’s first generation bin-picking 3D fringe projection scanner, and analysed, debugged, and optimised its existing programmes. In addition, he implemented a hardware triggering method that improved the data flow, which resulted in 2X increase in scanning speed, while achieving the framerate stability and consistency. This new improved product was demonstrated during the launch of SIMTech Innovation Factory. Upon further refinement of its calibration process, Shen Jian led the JMV team to extend the system’s capability for bin-picking solutions (Figure 1.), which opened up new business opportunities with Robotics integrators. Moving forward, JMV will continue to enhance it as a ready product via a joint-lab with A*STAR. For more enquiries, please contact Mr Lee Hock Wee, at [email protected] PAGE | 11

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Industry Assist Collaborative Industry Projects (CIPs), Initiatives, Programmes and Ready-To-Go Technologies are Available to Industry Assist Resource Efficiency Automated Optical Monitoring and Analytics Inspection (AOI) Platform (REMAP) This programme aims to develop and A platform that helps manufacturing co-develop advanced technologies companies in achieving sustainable that help manufacturers improve operations through resource efficiency. their quality and productivity by It includes smart management systems transforming and upgrading their for energy, water and waste. By providing current inspection process through the monitoring and analytics solutions, the latest advancement in optics it aims to assess equipment resource and automation. efficiency in real-time and identify hotspots of excessive resource usage. For enquiries, please contact Ms These hotspots can then be analysed Charlotte Lim at charlotte-lim@ to derive actionable items to achieve SIMTech.a-star.edu.sg quantifiable improvement. For enquiries, please contact Ms Cheryl Wong at [email protected]. edu.sg Collection & Delivery Inventory Planning Management System (CDMS) This programme aims to facilitate the decision-making and development This programme aims to equip companies of inventory policy.This is to control with a real-time collection and delivery rightsized inventory with the evolution management solution with Cloud- of data & analytics techniques to based Mobile Apps. This supports optimise inventory performance. courier/logistics industries in service improvement at reduced cost and time Sensorisation & Machine For enquiries, please contact Mr to achieve information accuracy, process Connectivity (S&C) Alex Tay Sheng Ru at alex_tay@ efficiency, and resource optimisation. SIMTech.a-star.edu.sg This programme helps resource For enquiries, please contact Mr Chai owners identify hidden capacities Lai Sing at [email protected] of their machines to improve manufacturing productivity. By tapping into equipment in the shop floor losses such as machine breakdown, machine slow-down and scrap parts, manufacturing companies can optimise the Overall Equipment Effectiveness (OEE) of their existing equipment. For enquiries, please contact PAGE | 13 Mr Wong Ming Mao at mmwong@ SIMTech.a-star.edu.sg

Upcoming Activities Events SIMTech – SkillsFuture Singapore Graduation Ceremony 2021, 24 November 2021 Organised by SIMTech and supported by SSG, the SIMTech-SkillsFuture Singapore Graduation Ceremony 2021 is an annual event which celebrates the accomplishment of individuals who have successfully completed the various Workforce Training programmes offered by SIMTech. This event will bring together leaders and office workers from various companies, as well as representatives from public sector agencies and industry associations, and serves a platform to strengthen the partnerships of A*STAR with the local public-private ecosystem in developing the human capital of Singapore’s manufacturing industry. This year, the event will include a segment on the SGUnited Skills (SGUS) Programme, which was designed to help unemployed or retrenched Singaporeans or Permanent Residents to acquire in-demand and emerging skills in manufacturing and related industries to improve their employability amidst the challenging job market disrupted by the COVID-19 pandemic. For enquiries, please contact Ms Zhang Yi at [email protected] Scan for more events Watch this space for more exciting upcoming events for 2021! Courses Graduate Diploma in Industrial Automation Graduate Diploma in Mechatronics Module 3: Control in Automation System Module 2: Enhance Control Performance of Precision 18 October 2021 | 6.30pm - 9.30pm | Zoom/ Machines SIMTech Premises 26 October 2021 | 6.30pm - 9.30pm | Zoom/ SIMTech Premises Understand the Microfluidics Manufacturing Processes SGUS for MedTech Product Manufacturing 19 October 2021 | 6.30pm - 9.30pm | Zoom/ Module 3: Control in Automation System SIMTech Premises 1 November 2021 | 9.00am - 6.00pm | Zoom/ SIMTech Premises Graduate Diploma in Additive Manufacturing Module 2: Powder-bed Additive Manufacturing Product Design and Innovation Processes for Complex Functional Metallic 9 November 2021 | 6.30pm - 9.30pm | Zoom/ Components SIMTech Premises 26 October 2021 | 6.30pm - 9.30pm | Zoom/ SIMTech Premises For course details and registration, please visit Scan for https://www.a-star.edu.sg/SIMTech/KTO more courses For general enquiries, please contact Tel: 6590 3193 or email: [email protected] Editorial Committee Ms Veronica Chiu Advisor Mr Alex Tay Member Editor Mr Tom Chua Member Ms Charlotte Lim Member Mr Darren Ong Member Ms Cheryl Wong Member Dr Yao Xiling Member Mr Hock Wee Ms Nurul Ain Designer Member PAGE | 14 All rights reserved. Copyright © SIMTech Singapore Institute of Manufacturing Technology, 2 Fusionopolis Way, #08-04, Innovis, Singapore 138634 For enquiries, please contact us at Tel: 6590 3199 | Email: [email protected] | Web: www.SIMTech.a-star.edu.sg

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