Subject: ADDITIVE MANUFACTURING (A.A. 2024/2025)
Unit Additive Manufacturing
To be chosen by the student (lesson)
The course aims at providing knowledge on additive manufacturing (AM) technologies, which are receiving increasing interest in industry and are being described as the third industrial revolution. Competence in this field is fundamental for the soon-to-be engineers who want to stay current with innovation and gain a portable career credential.
OVERVIEW OF AM
Basic principles of additive construction, from prototypes to end parts, evolution of AM definition.
AM cycle: file export, STL format, AMF format, STL processing, choice of orientation, slicing, supports, build process, post-processing.
Lab practice on STL processing and build preparation.
ASTM classification. Binder jetting (3DP): process, machines, materials, post-processing and finishing, properties and use.
Material extrusion (FDM): process, machines, materials, post-processing and finishing, properties and use.
Material jetting: process, machines, materials, post-processing and finishing, properties and use.
Plastic parts: post-processing, heat treatments, finishing operations.
Directed energy deposition. Powder Bed Fusion (SLS): process, machines, materials, post-processing and finishing, properties and use.
Powder Bed Fusion of metals: characterization of powders and of parts.
Powders Bed Fusion of metals: industrial management of the machine and of powders.
Design for Additive Manufacturing.
Lab practice on a fabrication job.
Current ASTM, F42 committee.
Uses of AM parts: conceptual models, form and fit models, functional models, final products. AM in industries: automotive, aerospace, defense, consumer, medical devices and prostheses, art and fashion, manufacturing and industrial, architecture.
Use of AM in tooling for polymers.
Use of AM in metal casting.
Economic/logistic considerations. Impact of AM in industry.
Developments of AM: trends in research.
SEMINARS – INDUSTRIAL EXPERTS
Remote lectures, laboratory exercises carried out online, individual and group projects, multimedia materials. Seminars by international experts and companies. Attendance is optional but strongly recommended for laboratories.
The evaluation includes a project work that is worth 10 points. The remanining 20 points are given on the oral exam, which starts from the discussion of the report and can cover any topic within the course contents.
Participants will learn the fundamentals of AM of polymers, metals, composites, and biomaterials; process capabilities (rate, cost, quality) and their relation to material characteristics, process parameters, and machine designs. Particular emphasis will be placed on metal-based AM technologies, for applications in the mechanics and automotive fields. Competences will include design, fabrication, and measurement of parts; discussion of how AM will influence existing business models in design and manufacturing, of major opportunities and needs for advancement.
Gibson, Ian, David W. Rosen, and Brent Stucker. Additive manufacturing technologies. New York: Springer, 2010.