CM4152 Solid Freeform Manufacturing Syllabus:

CM4152 Solid Freeform Manufacturing Syllabus – Anna University PG Syllabus Regulation 2021

COURSE OBJECTIVES:

 To acquaint the students with evolution of Solid Freeform Manufacturing (SFM) / Additive Manufacturing (AM), proliferation into various fields and its effects on supply chain.
 To gain knowledge on Design for Additive Manufacturing (DFAM) and its importance in quality improvement of fabricated parts.
 To acquaint with polymerization and sheet lamination processes and their applications.
 To acquaint with material extrusion and powder bed fusion processes.
 To gain knowledge on jetting and direct energy deposition processes and their applications.

UNIT I INTRODUCTION

Need – Development of SFM systems – Hierarchical structure of SFM – SFM process chain – Classification – Applications. Case studies: Bio printing- Food Printing- Electronics printing – Rapid Tooling – Building printing. AM Supply chain. Economics aspect: Strategic aspect- Operative aspect.

UNIT II DESIGN FOR ADDITIVE MANUFACTURING

Concepts and Objectives – AM Unique Capabilities – Part Consolidation – Topology Optimization – Lightweight Structures – DFAM for Part Quality Improvement – CAD Modeling – Model Reconstruction – Data Processing for AM – Data Formats – Data Interfacing – Part Orientation – Support Structure Design and Support Structure Generation – Model Slicing – Tool Path Generation. Design Requirements of Additive Manufacturing: For Part Production, For Mass Production, For Series Production. Case Studies.

UNIT III VAT POLYMERIZATION AND SHEET LAMINATION PROCESSES

Stereolithography Apparatus (SLA): Principles – Photo Polymerization of SL Resins – Pre Build Process – Part-Building and Post-Build Processes – Part Quality and Process Planning, Recoating Issues – Materials – Advantages – Limitations and Applications. Digital Light Processing (DLP) – Materials – Process – Advantages and Applications.
Laminated Object Manufacturing (LOM): Working Principles – Process – Materials, Advantages, Limitations and Applications. Ultrasonic Additive Manufacturing (UAM) – Process – Parameters – Applications. Case Studies.

UNIT IV MATERIAL EXTRUSION AND POWDER BED FUSION PROCESSES

Fused deposition Modeling (FDM): Working Principles – Process – Materials and Applications. Design Rules for FDM. Selective Laser Sintering (SLS): Principles – Process – Indirect and Direct SLS – Powder Structure – Materials – Surface Deviation and Accuracy – Applications. Multijet Fusion. Selective Laser Melting (SLM) and Electron Beam Melting (EBM): Principles – Processes – Materials – Advantages – Limitations and Applications. Case Studies.

UNIT V JETTING AND DIRECT ENERGY DEPOSITION PROCESSES

Binder Jetting: Three dimensional Printing (3DP): Principles – Process – Physics of 3DP – Types of printing: Continuous mode – Drop on Demand mode – Process – Materials – Advantages – Limitations – Applications. Material Jetting: Multi Jet Modelling (MJM) – Principles – Process – Materials – Advantages and Limitations. Laser Engineered Net Shaping (LENS): Processes- Materials- Advantages – Limitations and Applications. Case Studies.

COURSE OUTCOMES:

At the end of this course, the students shall be able to:
CO1: Relate the importance in the evolution of SFM/AM, proliferation into the various fields and its effects on supply chain.
CO2: Analyze the design for AM and its importance in the quality of fabricated parts.
CO3: Build knowledge on principles and applications of polymerization and sheet lamination processes with case studies.
CO4: Explain the principles of material extrusion and powder bed fusion processes and design guidelines.
CO5: Elaborate jetting and direct energy deposition processes and their applications.

REFERENCES:

1. Andreas Gebhardt and Jan-Steffen Hotter, “Additive Manufacturing:3D Printing for Prototyping and Manufacturing”, Hanser publications Munchen, Germany, 2016. ISBN:978-1-56990-582-1.
2. Ben Redwood, Brian Garret, FilemonSchöffer, and Tony Fadel, “The 3D Printing Handbook: Technologies, Design and Applications”, 3D Hubs B.V., Netherland, 2017. ISBN-13: 978-9082748505.
3. Ian Gibson, David W. Rosen and Brent Stucker, “Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing” Springer – New York, USA, 2nd Edition, 2015. ISBN13: 978-1493921126.
4. Liou, L.W. and Liou, F.W., “Rapid Prototyping and Engineering applications: A tool box for prototype development”, CRC Press, 1st Edition, 2007 FL, USA. ISBN- 9780849334092.
5. Milan Brandt., “Laser Additive Manufacturing 1st Edition Materials, Design, Technologies, and Applications”, Woodhead Publishing, UK, 2016. ISBN- 9780081004333.