Metals and materials

What we do

What’s new?

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First batch of stainless-steel powder atomised

The CSIR’s new ultrasonic atomiser facility has produced its first batch of 316L stainless steel powder – a high-quality material used in three-dimensional (3D) printing. Approximately 8 kg of powder was produced during this initial run. In additive manufacturing, 3D printing can be achieved through a technique called powder bed fusion, where an object is constructed layer by layer using a heat source to fuse powder particles together. South African businesses have traditionally relied on imported high-quality powders for this process. The ultrasonic atomiser machine was co-funded by the National Research Foundation, an entity of the Department of Science, Technology and Innovation.

Our Research

Vuyani Jarana
Advanced casting technologies

We specialise in developing casting techniques such as investment casting, semi-solid metal forming and high-pressure die casting. These processes enable the development of high-temperature alloys suitable in aerospace, automotive, medical and powder generation applications, including lightweighting applications. Castable alloys include aluminum, titanium, steel and magnesium. The hot isostatic press facility provides post-processing and heat treatment capabilities for a wide range of cast and additively manufactured components and alloys, adding significant value to the local industry.

Nomsa Dlamini
Powder metallurgy and testing services

The CSIR has advanced manufacturing facilities for metal powder atomisation, metal injection moulding and powder metallurgy processing of various metallic alloys and components. We focus on metals and composites, providing expert support in product development, prototyping, process development and materials testing. Our facilities are equipped to manufacture high-value components through powder metallurgy and hot isostatic pressing, producing metal alloy powders into near-net-shape finished products.

Contact information:

Dr Luyolo Mabhali
Acting Impact Area Manager
@email

Kgaladi Thema
Business Development and Commercialisation Manager
@email

 

Our facilities

Vuyani Jarana
Ultrasonic powder atomisation facility

The ultrasonic powder atomisation facility enables the production of high-quality spherical metal powders from metal wires and rods, reducing dependency on costly imports. It supports research and local industries that use advanced manufacturing techniques by offering powders with high purity, low oxygen levels, as well as excellent sphericity for varied applications. The first batch of 316L stainless steel powder was delivered in April 2025, shortly after the facility was established.

Nomsa Dlamini
Powder characterisation facility

The powder characterisation facility is used to analyse metal powders for their physical and functional properties, as required for various manufacturing processes and industrial applications. It is ISO17025:2017 SANAS T0381 accredited. The facility is equipped to assess particle size, shape, density, surface area and chemical composition. It adds value by providing insights into the flowability and rheology of metal powders – critical factors for additive manufacturing, metal injection moulding and powder metallurgy processes.

Fabrizio Dionisio
Metal injection moulding facility

The metal injection moulding facility enables the cost-effective production of complex metal components from powder feedstocks. It offers design-to-production services to support local enterprises with the precision manufacturing of small- to medium-size parts in high volumes. The facility aims to industrialise metal injection moulding technology in South Africa and provides a means for import substitution and the localisation of a wide range of products currently imported into the country.

Fabrizio Dionisio
Investment casting facility

Investment casting is a traditional manufacturing process that uses the lost wax method to produce intricate metal components with minimal machining. Our facility – South Africa's only production-level vacuum casting foundry – advances this process with capabilities in titanium and other alloys, supporting industry through research and development.

Fabrizio Dionisio
Hot isostatic press facility

The hot isostatic press facility has been established to support advanced manufacturing, industrialisation and commercialisation by enhancing the quality and densification of finished metal components. Key processing specifications for selected components include pressure, temperature and weight. The facility serves various advanced and critical applications in the aerospace, medical and defense sectors by ensuring optimal density in processed parts and improving creep and fatigue resistance.

Fabrizio Dionisio
Non-destructive testing and metrology facility

We support local industries through non-destructive evaluation and metrology services, including infrared thermographic and ultrasonic testing. Our dedicated laboratory is equipped with X-ray and phased array systems for detecting defects in metal and composite components. The team also conducts structural analysis, corrosion testing and forensic investigations for failure analysis – crucial for quality assurance and risk mitigation across various applications.

Fabrizio Dionisio
Mechanical testing facility

The mechanical testing facility provides high-quality materials testing services to support research, development and industrial needs. The facility is ISO/IEC 17025:2017 accredited, ensuring internationally recognised quality and competence in mechanical testing. Our experts deliver reliable and precise test results. Testing capabilities include accredited and non-accredited tests. Accredited tests comprise tensile testing, fatigue testing and fracture toughness testing. Non-accredited tests include compression testing, hardness testing, three-point bend testing, fracture toughness testing and fracture crack propagation testing.

National Programmes

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Vuyani Jarana
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Nomsa Dlamini
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Fabrizio Dionisio
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