Additive manufacturing (BME714A)

Additive manufacturing

Course Code BME714A 
CIE Marks 50
Teaching Hours/Week (L: T:P: S) 3­0­0­0 
SEE Marks 50
Total Hours of Pedagogy 40 
Total Marks 100
Credits 03 
Exam Hours 03
Examination nature (SEE) Theory

Module­ 1

Introduction and basic principles: Need for Additive Manufacturing, Generic AM process, stereo

lithography or 3dprinting, rapid prototyping, the benefits of AM, distinction between AM and CNC

machining, other related technologies­ reverse engineering technology.

Development of Additive Manufacturing Technology: Introduction, computers, computer­aided

design technology, other associated technologies, the use of layers, classification of AM processes,

metals systems, 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.

Module­ 2

Photo polymerization processes: Stereo lithography (SL), Materials, SL resin curing process,

Micro­ Stereo lithography, Process Benefits and Drawbacks, Applications of Photo polymerization

Processes.

Powder bed fusion 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.

Extrusion­based systems: Fused Deposition Modelling (FDM), Principles, Materials, Plotting and

path control, Bio­Extrusion, Process Benefits and Drawbacks, Applications of Extrusion­Based

Processes.

Module ­3

Printing Processes: evolution of printing as an additive manufacturing process, research

achievements in printing deposition, technical challenges of printing, printing process modelling,

material modification methods, three­dimensional 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 –based DW, laser transfer, DW thermals pray, DW

beam deposition, DW liquid­phase direct deposition.

Module­ 4

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 non­thermal techniques and thermal techniques.

Module­ 5

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: Examples for Aerospace, defence, automobile, Bio­medical and general

engineering industries. Direct digital manufacturing: Align Technology, Siemens and Phonak, DDM

drivers, manufacturing vs. prototyping, lifecycle costing, future of direct digital manufacturing.

Suggested Learning Resources:

Books

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 4419­1119­3 e­ISBN: 978­ 1­4419­ 1120­9 DOI 10.1007/978 ­1­4419­ 1120­9

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

2003

3. Rapid Prototyping: Theory & Practice Ali K. Kamrani, Springer 2006 Emand Abouel Nasr,

4. Rapid Manufacturing: The Technologies and Applications of Rapid Prototyping and Rapid

Tooling” D.T. Pham, S.S. Dimov Springer 2001

5. Rapid Prototyping: Principles and Applications in Manufacturing Rafiq Nooran John Wiley &

Sons 2006

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

7. Understanding additive manufacturing: rapid prototyping, rapid tooling, rapid manufacturing

Andreas Gebhardt