Additive Manufacturing: Tools, Materials and Methods

Aim

This course will provide a general understanding of additive manufacturing (3D-printing), and detailed understanding of:

• the physics and chemistry involved with the various printing methods, including the material requirements,
• the types of materials appropriate for various printing methods,
• various printing methods, their advantages and disadvantages,
• current and future applications of additive manufacturing.

After completing this course, students will be able to:

• describe several types of 3D printers, their mode of operation, and their strengths and limitations,
• determine which type of printer is most suitable for fabricating a part based on the requirements of the desired product (choice of material, tolerances, etc.), or whether 3D printing is at all a viable option,
• prepare 3D CAD models for creating printed devices (including editing for printer limitations, etc.), and
• confidently produce 3D-printed devices with at least two kinds of 3D printers (after hands-on work in the labs).

Content

Material properties in the solid, liquid, and other (gel, glass) states. Phase-change processes and chemical reactions, including photo-initiated chemistry. Introduction to digital control of mechanical systems (stepper motors, etc.) Introduction to fluid mechanics, as applied to additive manufacturing. Introduction to surface science, as applied to additive manufacturing. Applications, strengths, and weaknesses of various forms of additive manufacturing including: Mechanical applications (prototypes, mechanical components), chemical and life-science applications (prosthetics, artificial organs, lab-on-a-chip devices, etc.). An introduction to 3D CAD. An introduction to planning/slicing software. Hands-on design, fabrication, and evaluation of fabricated parts.