Module:

Latest Module Specifications

Current Academic Year 2025 - 2026

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Module Title
Module Code	(ITS: MM602)
Faculty		School
NFQ level		Credit Rating

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. 1E14811C-80B4-0001-6F58-1CB61EDF1B23
2. Critique the differences in Additive Manufacturing according to technique and material class
4. 7,6
5. 1
6. 1E14811D-BA99-0001-81E4-16D11C90144D
7. Develop and optimize Additive Manufacturing techniques for new materials, composites and multi-material parts
9. 7,12,15,6,10
10. 2
11. 1E14811D-EA54-0001-BE6B-FC7D10901588
12. Construct basic models of Additive Manufacturing processes to understand material evolution during the Additive Manufacturing process and prediction of the final part properties.
14. 20,7,12,15,6,13,19,21,14,11,9
15. 3
16. 1E14811F-2D6E-0001-81F2-1AF014A01CBB
17. Develop the design for Additive Manufacturing method to optimise the topology, functional performance and product life considerations including manufacturability, reliability, and cost.
19. 7,12,15,6,13,8,14,11,9,10
20. 4
21. 1E14811F-558E-0001-AB62-175C15501FA9
22. Formulate design of experiments for built part characterization for process control.
24. 7,6,8,11,9
25. 5
26. 1E14811F-6553-0001-FF23-D0E36B10D040
27. Critique health and safety impacts, requirements and compliance.
29. 7,12,15,6,13,14
30. 6

*Type*	*Hours*	*Description*
Workload	Full time hours per semester
Lecture	32	According to indicative content and learning outcomes
Fieldwork	40	CAD designing and topology optimisation
Online activity	58	Reading and using module preparatory resources
Independent Study	58	Study of module content prior to exam
Total Workload: 188

Type	Description	% of total	Assessment Date
Assessment Breakdown
Assignment	Critique the technical merits of AM case study.	25%	n/a
Assignment	Develop a business plan for AM case study.	25%	n/a
Assignment	Formulate a life cycle analysis energy assessment of AM compared to traditional manufacturing.	25%	n/a
Assignment	Design optimisation including lattice stucture for part manufactured by AM.	25%	n/a

Reassessment Requirement Type
Resit arrangements are explained by the following categories; RC1: A resit is available for both^* components of the module. RC2: No resit is available for a 100% coursework module. RC3: No resit is available for the coursework component where there is a coursework and summative examination element. ^* ‘Both’ is used in the context of the module having a coursework/summative examination split; where the module is 100% coursework, there will also be a resit of the assessment

Pre-requisite	None
Co-requisite	None
Compatibles	None
Incompatibles	None

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

Indicative Reading List

Books:

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

Articles:
None

Other Resources

None