Course Learning Objectives:

    • Gain an understanding of the general design rules/guidelines pertaining to polymer and metal additive manufacturing via DfAM exercises.
    • Know the best practices of safety aspects while working with 3D printing. 
    • Learn how to do Finite Element Analysis (FEA) and apply it for 3D printing by incorporating the entire FEA workflow.
    • Carry out 3D printing on an industrial grade machine that includes slicer software, machine setup, build, post-processing, etc.
Course Topics:

 

  • Module 1 – Design for Additive Manufacturing (DfAM): Fundamentals and Principles
    Introduction to design, DfAM case studies, support structures, stress concentration, residual stress, general AM design rules, polymer AM general design rules, metal AM general design rules, standard DfAM workflow.
  • Module 2 – AM: Environment, Health and Safety
    Introduction to environment, health, and safety; 3D printing hazards; best practices; personal protective equipment; waste disposal; safety signs; safety precautions; machine-specific examples; key environment, health, and safety organizations; and AM safety quiz.
  • Module 3 – Design for Additive Manufacturing (DfAM): Advanced Strategies and Applications
    Intermediate CAD, DfAM exercises, efficient design techniques, designing 3D-printed joints, tolerances, slicer software, best practices, material selection, engineering aspects of product design.
  • Module 4 – Finite Element Analysis (FEA)
    Introduction to engineering problems, importances of FEA, objectives of FEA, stress-strain behavior, FEA workflow, 3DEXPERIENCE SIMULIA Abaqus, FEA validation checks, practical FEA exercises for metal and polymer AM 3D-printed parts.
  • Module 5 – Industrial Grade 3D Printing
    3D printing demo on the Stratasys F900, slicer software demo, machine setup, build, post-processing, reverse engineering demo, lab tour.
Course Outcomes:
 
By the end of the course, participants will be able to:

 

  • Apply the DfAM rules/ guidelines prior to manufacturing a 3D printed part.
  • Design AM parts in the most efficient manner with minimum support structures.
  • Understand the basic terms and definitions associated with environment, health & safety in AM.
  • Identify common risks associated with AM.
  • Be enabled to take preventative actions to minimize and mitigate risks.
  • Explain the typical FEA workflow.
  • Analyze the part prior to 3D printing and predict its behavior under real-world loading conditions via FEA simulations.
  • Create a part on an industrial grade 3D printing machine.