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Subject: ADDITIVE MANUFACTURING OF AUTOMOTIVE COMPONENTS (A.A. 2021/2022)

master degree course in ADVANCED AUTOMOTIVE ENGINEERING

Course year 2
CFU 6
Teaching units Unit Additive Manufacturing of Automotive Components
To be chosen by the student (lesson)
  • TAF: Optional subjects SSD: ING-IND/16 CFU: 6
Teachers: Elena BASSOLI
Moodle portal

Aula virtuale su Microsoft Teams (immatricolati: 2020)

in attesa di attivazione da parte del docente

Exam type written
Evaluation final vote
Teaching language inglese
Contents download pdf download

Teachers

Elena BASSOLI

Overview

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.

Admission requirements

None

Course contents

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.

AM PROCESSES
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.

STANDARDS
Current ASTM, F42 committee.

APPLICATIONS
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

Teaching methods

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 course is held entirely in English.

Assessment methods

The exam includes a practical test on the use of Materialize Magics, to be held live at the beginning of the oral exam and lasting about 15 minutes, and an oral exam in English. Each of the two tests is evaluated up to a maximum of 10 points, to which the evaluation of the individual project is added up to a maximum of 10 points. The final grade is obtained from the sum of the three scores. During the tests it is not allowed to consult any material. The oral exam verifies, through the request for comparisons and critical evaluations, the ability to apply the knowledge developed.

Learning outcomes

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.

Similar courses
http://www.sme.org/rtam-certificate-program/
http://professional.mit.edu/programs/short-programs/additive-manufacturing
http://www.online.colostate.edu/courses/MECH/MECH502.dot

Readings

Gibson, Ian, David W. Rosen, and Brent Stucker. Additive manufacturing technologies. New York: Springer, 2010.