Faculty Name: Dr. Muvvala Gopinath

Course Name: Additive Manufacturing Technology (ME50909)

Course Period: 04 ^th Sep to 25 ^th Nov 2024 (Monday 7:30 PM to 08:55 PM; Wednesday 06:00 PM to 07:25 PM)

Number of Credits: 2 credits

Course Contents: Overview of Additive Manufacturing: Product Development Cycle in additive Manufacturing process, virtual prototyping, physical prototyping, Solid Modelling: Data formats, conversion, checking, repairing and transmission. Synergic integration technologies, Part slicing and Build Orientation, Area-filling strategies, applications and limitations of Additive Manufacturing. Classification of Additive Manufacturing processes: Sheet Lamination, Material Extrusion, Photo-polymerization, Powder Bed Fusion, Binder Jetting, Direct Energy Deposition. Popular additive manufacturing processes. Selection of rapid prototyping, tooling and manufacturing systems based on product requirements. Energy sources and their interactions with feedstock. Design for Additive Manufacturing (DfAM). Demonstration on open-source pre-processing tools.

What you'll learn: In the course on Additive Manufacturing Technology, students will gain comprehensive insights into the entire additive manufacturing cycle, covering pre-processing, processing (additive manufacturing technologies), and post-processing stages. The pre-processing segment addresses critical aspects such as CAD model tessellation and error management, encompassing various file formats essential for compatibility and accuracy. Techniques for CAD model slicing will be explored to optimize printing processes, including selection criteria for part orientation, crucial for achieving desired outcomes like improved surface finish and geometrical accuracy. Also, the infill strategies addressing various needs for lightweight engineering applications will be covered. The course further delves into scan strategies and their impact on residual stresses, anisotropy, and mechanical properties of printed parts. Moving into the processing phase, students will study the technological advancements and underlying physics of diverse additive manufacturing processes. These include Directed Energy Deposition, Powder Bed Fusion, Material Extrusion, Sheet Lamination, VAT Photopolymerization, Binder Jetting, and other emerging techniques. Each method's operational principles, advantages, and limitations will be thoroughly examined to provide a comprehensive understanding of their applications across various industries. Post-processing methods play a pivotal role in refining the surface finish and properties of printed components. Techniques for enhancing surface quality, such as polishing, machining, or chemical treatments, shot and shock peening will be discussed in detail. Moreover, the course will introduce students to monitoring techniques crucial for adaptive control within additive manufacturing processes, ensuring consistent and predictable manufacturing outcomes. A significant focus of the course lies in Design for Additive Manufacturing (DfAM) principles, emphasizing guidelines and strategies tailored for optimizing designs to leverage the unique capabilities of additive manufacturing technologies. This includes considerations like minimizing support structures, optimizing geometries for better printability, strength and performance, and integrating functionalities that conventional manufacturing methods may find challenging to replicate. By the course's conclusion, students will emerge equipped with a comprehensive understanding of additive manufacturing technologies and their practical applications across industries as few case studies will also be highlighted. They will be proficient in navigating the additive manufacturing cycle from CAD model preparation through to post-processing and possess the knowledge to implement effective design strategies that capitalize on the advantages of additive manufacturing. This holistic education prepares students to innovate in product development, streamline manufacturing processes, and contribute to advancements in the rapidly evolving field of additive manufacturing.