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Module Specifications.

Current Academic Year 2024 - 2025

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Date posted: September 2024

Module Title Additive Manufacturing - polymer, metal, ceramic & multi-materials
Module Code MM602 (ITS) / MEC1074 (Banner)
Faculty Engineering & Computing School Mechanical & Manufacturing Eng
Module Co-ordinatorEanna Mccarthy
Module TeachersDermot Brabazon, Inam Ul Ahad, Joan Kelly
NFQ level 9 Credit Rating 7.5
Pre-requisite Not Available
Co-requisite Not Available
Compatibles Not Available
Incompatibles Not Available
Coursework Only
Repeat the four assignments. Lectures are available on-line.
Description

The objectives of this module are to enable participants to understand the basic and advanced knowledge about Additive Manufacturing (AM) process. The module covers major AM techniques for metal, polymer and ceramics. The participants will learn detailed design process, from conceptualization to creation of part design for a specific material and AM process. Development of new materials for AM, production of composites and multi-material via 3D printing, and sustainability of AM processes will be covered. Participants will learn about in-situ monitoring techniques, data analysis, process control and health and safety issues. Introduction to modelling of AM processes will be covered. The participants will learn about the part topology and design optimization using latest software (SOLIDWORKS Topology Optimization and Live Parts™).

Learning Outcomes

1. Critique the differences in Additive Manufacturing according to technique and material class
2. Develop and optimize Additive Manufacturing techniques for new materials, composites and multi-material parts
3. Construct basic models of Additive Manufacturing processes to understand material evolution during the Additive Manufacturing process and prediction of the final part properties.
4. Develop the design for Additive Manufacturing method to optimise the topology, functional performance and product life considerations including manufacturability, reliability, and cost.
5. Formulate design of experiments for built part characterization for process control.
6. Critique health and safety impacts, requirements and compliance.



Workload Full-time hours per semester
Type Hours Description
Lecture32According to indicative content and learning outcomes
Fieldwork40CAD designing and topology optimisation
Online activity58Reading and using module preparatory resources
Independent Study58Study of module content prior to exam
Total Workload: 188

All module information is indicative and subject to change. For further information,students are advised to refer to the University's Marks and Standards and Programme Specific Regulations at: http://www.dcu.ie/registry/examinations/index.shtml

Indicative Content and Learning Activities

Additvite Manufacturing Process
Additive manufacturing processes for metals (PBF/SLM, DED/LENS, Ink Jet), polymers (STL, SLS, FDM, Material jetting), and ceramics (SLS, SLM, FDM, SL, DIP).

Composite and Multimaterial 3D Printing
Production of composites via additive manufacutirng and multi-material 3D printing.

Material and Process Development for Additive Manufacturing
Development of new materials (composites, nano-reinforced, etc.) and corresponding techniques for metal and polymer additive manufacturing and

Additive Manufacturing Process Characterisation
In-situ monitoring data analysis and process control.

Modelling of Additive Manufacturing Processes
Understanding of thermal models used for additive manufacturing processes.

Design for Additive Manufacturing
Sustainability of AM (material, energy, weight and time saving, prototyping, economic sustainability, and hybrid AM systems). Case studies on AM. Laboratory exercises: CAD design, topology optimization (defining loads, constraints and boundary conditions), topology optimisation to CAD conversion.

Health and Safety for Additive Manufacturing
ATEX compliance, chemical safety for polymers and metals, laser safety, laboratory layout considerations

Assessment Breakdown
Continuous Assessment100% Examination Weight0%
Course Work Breakdown
TypeDescription% of totalAssessment Date
AssignmentCritique the technical merits of AM case study.25%n/a
AssignmentDevelop a business plan for AM case study.25%n/a
AssignmentFormulate a life cycle analysis energy assessment of AM compared to traditional manufacturing.25%n/a
AssignmentDesign optimisation including lattice stucture for part manufactured by AM.25%n/a
Reassessment Requirement Type
Resit arrangements are explained by the following categories:
Resit category 1: A resit is available for both* components of the module.
Resit category 2: No resit is available for a 100% continuous assessment module.
Resit category 3: No resit is available for the continuous assessment component where there is a continuous assessment and examination element.
* ‘Both’ is used in the context of the module having a Continuous Assessment/Examination split; where the module is 100% continuous assessment, there will also be a resit of the assessment
This module is category 1
Indicative Reading List

  • Phillips, William H.: 2016, Additive manufacturing: opportunities, challenges, implications, 1634842324
  • White, Lillian: 2015, Additive manufacturing materials: standards, testing & applicability, 9781634833028
  • Shamsaei, Nima; Usher, John; Bian, Linkan: 2018, Laser-based additive manufacturing of metal parts: modeling, optimization, and control of mechanical properties, 9781498739986
  • Zohdi, Tarek I: 2018, Modeling and Simulation of Functionalized Materials for Additive Manufacturing and 3D Printing: Continuous and Discrete Media: Continuum and Discrete Element Methods, 9783319700793
  • Khorram Niaki, Mojtaba: 2018, The Management of Additive Manufacturing: Enhancing Business Value, 9781447173649
  • Um, Dugan: 2018, Solid Modeling and Applications: Rapid Prototyping, CAD and CAE Theory,, 9783319745947
  • Yang, Li: 2017, Additive manufacturing of metals: the technology, materials, design and production, 3319551272
  • Pandey, Pulak M.; Kumar, L. Jyothish.; Wimpenny, David Ian: 2017, Advances in 3D Printing & Additive Manufacturing Technologies, 9789811008122
  • Savalani, Monica Mahesh; Muthu, Subramanian Senthilkannan: 2016, Handbook of sustainability in additive manufacturing. Volume 1, 9789811005473
  • Savalani, Monica Mahesh; Muthu, Subramanian Senthilkannan: 2016, Handbook of sustainability in additive manufacturing. Volume 2, 9789811006043
  • Brandt, Milan: 2016, Laser additive manufacturing: materials, design, technologies, and applications, 9780081004333
  • Hoath, Stephen D.: 0, Fundamentals of inkjet printing: the science of inkjet and droplets, 9783527684731
  • Thornton, Albert: 2015, Additive manufacturing (AM): emerging technologies, applications and economic implications, 9781634638500
Other Resources

None

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