Unit 1

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), Jetting, 3D Printing, Laser Engineering Net Shaping (LENS), Laminated Object Manufacturing (LOM), Electron Beam Melting (EBM) Capabilities, materials, costs, advantages and limitations of different systems.

Unit 2

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, Process evaluation: process-structure relationships, structure property relationships, 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

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, rasterisation, part Orientation and support generation.

Laboratory:
CAD Modeling: Introduction to CAD environment, Sketching, Modeling and Editing features, Different file formats, Export/Import geometries, Part orientation, Layer slicing, Process path selection, Printing, Numerical and experimental evaluation.

Course Objectives

• To provide comprehensive knowledge of the wide range of additive manufacturing processes, capabilities and materials
• To understand the software tools and techniques used for additive manufacturing.
• To create physical objects that facilitates product development/prototyping requirements.

Course Outcomes

• CO1: Demonstrate appropriate level of understanding on principles of additive manufacturing processes.
• CO2: Choose appropriate materials for additive manufacturing processes
• CO3: Apply suitable CAD tools and CAD interface for additive manufacturing process
• CO4: Develop physical prototypes by identifying suitable process with optimum process parameters

CO – PO Mapping

Textbook(s)

• Gibson, I., Rosen, D.W. and Stucker, B., “Additive Manufacturing Methodologies: Rapid Prototyping to Direct Digital Manufacturing”, Springer, 2015.
• Chua, C.K., Leong K.F. and Lim C.S., “Rapid prototyping: Principles and applications”, Third edition, World Scientific Publishers, 2010.

Reference(s)

• Liou, L.W. and Liou, F.W., “Rapid Prototyping and Engineering applications: A tool box for prototype development”, CRC Press, 2011.
• Kamrani, A.K. and Nasr, E.A., “Rapid Prototyping: Theory and practice”, Springer, 2006.
• Hilton, P.D. and Jacobs, P.F., Rapid Tooling: Technologies and Industrial Applications, CRC Press, 2000

Evaluation Pattern