| Module Title |
Additive Manufacturing - polymer, metal, ceramic & multi-materials |
| Module Code |
MEC1074 (ITS: MM602) |
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Faculty |
Mechanical & Manufacturing Eng |
School |
Engineering & Computing |
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NFQ level |
9 |
Credit Rating |
7.5 |
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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™).
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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.
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| Workload | Full time hours per semester | | Type | Hours | Description |
|---|
| 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 |
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| Section Breakdown | | CRN | 20406 | Part of Term | Semester 2 | | Coursework | 0% | Examination Weight | 0% | | Grade Scale | 40PASS | Pass Both Elements | Y | | Resit Category | RC1 | Best Mark | N | | Module Co-ordinator | Eanna Mccarthy | Module Teacher | Dermot Brabazon, Inam Ul Ahad, Joan Kelly |
| | Section Breakdown | | CRN | 21162 | Part of Term | Semester 2 | | Coursework | 0% | Examination Weight | 0% | | Grade Scale | 40PASS | Pass Both Elements | Y | | Resit Category | RC1 | Best Mark | N | | Module Co-ordinator | Eanna Mccarthy | Module Teacher | |
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| Assessment Breakdown |
| Type | Description | % of total | Assessment Date |
|---|
| 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
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Pre-requisite |
None
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Co-requisite |
None |
| Compatibles |
None |
| Incompatibles |
None |
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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
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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
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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 |
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