18ME741 Additive Manufacturing syllabus for ME

Introduction and basic principles:

Need for Additive Manufacturing, Generic AM process, stereoli tho graphy or 3dprinting, rapid proto typing ,the benefits of AM, distinction between AM and CNC machining, other related technologies- reverse engineering technology.

Development of Additive Manufacturing Technology:

Introduction, computers, computer-aidedde sign technology ,other associated technologies, the use of layers, classification of AM processes, metals ystems, hybrid systems, milestones in AM development.

Additive Manufacturing Process chain:

Introduction, the eight steps in additive manufacture, variations from one AM machine to another ,metal systems, maintenance of equipment, materials handling issues, design for AM, and application areas.

Photo polymerization processes:

Stereolitho graphy (SL), Materials, SL resin curing process, Micro-stereoli thography, Process Benefits and Drawbacks, Applications of Photo polymerization Processes.

Powder bedfusion processes:

Introduction, Selective laser Sintering (SLS), Materials, Powder fusion mechanism, SLS Metal and ceramic part creation, Electron Beam melting (EBM), Process Benefits and Drawbacks, Applications of Powder Bed Fusion Processes.

Extrusion-based systems:

Fused Deposition Modelling (FDM), Principles, Materials, Plotting and path control, Bio-Extrusion, Process Benefits and Drawbacks, Applications of Extrusion-Based Processes.

Printing Processes:

evolution of printing as an additive manufacturing process, research achievements in printing deposition, technical challenges of printing, printing process modeling, material modification methods, three-dimensional printing, advantages of binder printing

Sheet Lamination Processes:

Materials, Laminated Object Manufacturing (LOM), Ultrasonic Consolidation (UC), Gluing, Thermal bonding, LOM and UC applications.

Beam Deposition Processes:

introduction, general beam deposition process, description material delivery, BD systems , process parameters, typical materials and microstructure, processing–structure–properties relationships, BD benefits and drawbacks.

Direct Write Technologies:

Background ,ink -basedDW,laser transfer, DW thermals pray,DW beam deposition,DW liquid-phase directde position.

Guidelines for Process Selection:

Introduction, selection methods for apart, challenges of selection, example system for preliminary selection, production planning and control.

Software issues for Additive Manufacturing:

Introduction, preparation of cad models – the STL file, problems with STL files, STL file manipulation.

Post- Processing:

Support material removal, surface texture improvements, preparation for use as a pattern, property enhancements using non-thermal techniques and thermal techniques.

The use of multiple materials in additive manufacturing:

Introduction, multiple material approaches, discrete multiple material processes, porous multiple material processes, blended multiple material processes, commercial applications using multiple materials, future directions.

AM Applications:

Functional models, Pattern for investment and vacuum casting, Medical models, art models, Engineering analysis models, Rapid tooling, new materials development, Bi-metallic parts, Remanufacturing. Application: Examples for Aerospace, defense, automobile, Bio-medical and general engineering industries.

Direct digital manufacturing:

Align Technology, siemens and phonak, DDM drivers, manufacturing vs. prototyping, life- cycle costing, future of direct digital manufacturing.

Course Outcomes:

At the end of the course the student will be able to:

CO1: Demonstrate the knowledge of the broad range of AM processes, devices, capabilities and materials that are available.

CO2: Demonstrate the knowledge of the broad range of AM processes, devices, capabilities and materials that are available.

CO3: Understand the various software tools, processes and techniques that enable advanced/additive manufacturing.

CO4: Apply the concepts of additive manufacturing to design and create components that satisfy product development/prototyping requirements, using advanced/additive manufacturing devices and processes.

CO5: Understand characterization techniques in additive manufacturing.

CO6: Understand the latest trends and business opportunities in additive manufacturing.

Question paper pattern:

• The question paper will have ten full questions carrying equal marks.
• Each full question will be for 20 marks.
• There will be two full questions (with a maximum of four sub- questions) from each module.
• Each full question will have sub- question covering all the topics under a module.
• The students will have to answer five full questions, selecting one full question from each module.

Textbook/s

1 Additive Manufacturing Technologies Rapid Prototyping to Direct Digital Manufacturing I. Gibson l D. W. Rosen l B. Stucker Springer New York Heidelberg Dordrecht, London ISBN: 978-1- 4419-1119-3 e-ISBN: 978- 1-4419- 1120-9 DOI 10.1007/978 -1-4419- 1120-9

Reference Books

1 “Rapid Prototyping: Principles & Applications Chua Chee Kai, Leong Kah Fai World Scientific 2003

2 Rapid Prototyping: Theory & Practice Ali K. Kamrani, Springer 2006 EmandAbouel Nasr,

3 Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and Rapid Tooling” D.T. Pham, S.S. Dimov Springer 2001

4 Rapid Prototyping: Principles and Applications in Manufacturing RafiqNooran John Wiley & Sons 2006

5 Additive Manufacturing Technology Hari Prasad, A.V.Suresh Cengage 2019

6 Understanding additive manufacturing: rapid prototyping, rapid tooling, rapid manufacturing Andreas Gebhardt Hanser Publishers 2011