Unit 1

10 Hours

Introduction: Methods and Systems: Introduction to layered manufacturing, Importance of Additive Manufacturing, Additive Manufacturing in Product Development. Classification of additive manufacturing processes, Common additive manufacturing technologies; Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Stereo Lithography (SLA), Selection Laser Melting (SLM), Digital Laser Processing (DLP), Jetting, 3D Printing, Laser Engineering Net Shaping (LENS), Laminated Object Manufacturing (LOM), Electron Beam Melting (EBM), Wire Arc Additive Manufacturing (WAAM), Electro Chemical AM, 4D Printing. Capabilities, materials, costs, advantages, and limitations of different systems.

Unit 2

10 Hours

Material and Process Evaluation: Material science for additive manufacturing – Mechanisms of material consolidation. FDM, SLS, SLM, 3D printing, and jetting technologies. Polymers coalescence and sintering, photopolymerization, solidification rates, Meso and macro structures, Additive Manufacturing of composite materials. Process evaluation: process-structure relationships, structure-property relationships, Post-processing: Heat treatment, shot peening, HIPS, Micro finishing of AM parts, Applications: Prototyping, Industrial tooling, Aerospace, Automobile, Medical etc., Quality control and reliability: Defects in FDM, SLS and SLM, Critical process parameters: geometry, temperature, composition, phase transformation, Numerical and experimental evaluation: roles of process parameter combination, process optimization.

Unit 3

10 Hours

CAD in Additive Manufacturing: CAD Modelling for 3D printing: 3D Scanning and digitization, data handling &reduction Methods, AM Software: data formats and standardization, Slicing algorithms: uniform flat layer slicing, adaptive slicing, Process-path generation: Process-path algorithms, rasterization, part Orientation and support generation. Design for Additive Manufacturing: Design for minimum material usage, Topology design optimization, Mass customization, Generative Design, Part consolidation, Design guidelines for extrusion, liquid and powder-based AM.

Course Objective

• To make students understand the wide range of additive manufacturing processes, capabilities, and materials
• To provide comprehensive knowledge of the various software tools and techniques that enable additive manufacturing.
• To make the students learn to create physical objects that satisfy product development/ prototyping requirements, using/ additive manufacturing processes.

Course Outcomes

CO1: Understanding the principles of various additive manufacturing processes

CO2: Demonstrate competency in the behaviour of materials used for additive manufacturing processes

CO3: Interface CAD tools effectively with additive manufacturing systems

CO4: Identify suitable additive manufacturing processes, define optimum process parameters, and develop physical prototypes using suitable additive manufacturing systems

CO-PO Mapping

Skills Acquired

Selection of suitable additive manufacturing technique for a given application, finishing of additive manufactured part, CAD data transfer to additive manufacturing, technology for metal additive manufacturing

1. Gibson, I., Rosen, D.W. and Stucker, B., “Additive Manufacturing Methodologies: Rapid Prototyping to Direct Digital Manufacturing”, Springer, 2010.
2. Chua, C.K., Leong K.F. and Lim C.S., “Rapid prototyping: Principles and applications”, second edition, World Scientific Publishers, 2010.
3. Liou, L.W. and Liou, F.W., “Rapid Prototyping and Engineering applications : A tool box for prototype development”, CRC Press, 2011.
4. Kamrani, A.K. and Nasr, E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006.
5. Hilton, P.D. and Jacobs, P.F., “Rapid Tooling: Technologies and Industrial Applications”, CRC press, 2005.