Course syllabus

ADDITIVE MANUFACTURING – MTT120

Spring 2024

 

1. Aim

The aim is to establish a basic understanding regarding additive manufacturing (AM) as the industrial method for prototyping and manufacture of advanced components for various industrial sectors. The course covers overview of seven additive manufacturing technology groups as well as general overview of the AM manufacturing chain, including pre-processing, components design for AM, process know-how, materials selection and basic aspects of manufacturing of metallic, polymeric and ceramic products as well as their composites with respect to materials and processing technologies.

 

2. Learning outcomes

After completion of the course, you should be able to:

• describe basic principles for additive manufacturing;
• describe the main processes for the additive manufacturing and their capabilities and limitations;
• demonstrate basic skills with respect to design for additive manufacturing;
• understand and describe the design, materials and processing aspects of the AM processes for metallic materials and some polymeric and ceramic materials;
• describe technical limitations/product realization capabilities when applying additive manufacturing technology as manufacturing method;
• understand and be able to analyze conditions set by materials technology, for in particular powder-bed and blown powder/wire-based processes.    

3. Contents

The course addresses following topics:

• Basic terminology, definitions and technologies in additive manufacturing;
• Preparation/design for AM, including the steps from product design to manufacturing;
• Applications for AM with respect to types of products, appropriate manufacturing series and so on;
• Basics about AM processing, including characteristics of different AM technologies;
• Technology and methods applied for metals, polymers and ceramics;
• Basics of materials technology and powder technology of relevance in AM;
• Quality control of AM-parts;
• Integration of AM in manufacturing chain;
• Properties of AM components;
• Post-processing of AM-parts in dependence on requirements to the components, AM technology and material;
• Application of AM in different fields and future perspectives of the technology.

4. Organisation

The course includes a lecture series that covers the main topics of the course, as defined in the course plan. Several guest lecturers from industry (technology providers, end-users as well as manufacturers of AM parts) will also contribute with their knowledge and industrial perspective on additive manufacturing. Some invited lectures will be given using Zoom. On-campus lectures, meeting with the groups, visit to the labs and some “office days” are scheduled to maximize possibility for physical interaction.

The course includes a compulsory project group assignment, which is organized to train participants in design, manufacture and evaluation of AM components. The project is presented both, by written report and oral presentation.

Besides the lecture series, number of tutoring events/exercises/practical sessions will be held. During these events, you will be trained in design/process preparation for polymer and metal AM, AM processing knowledge, critical aspects of materials technology in AM and AM applications. In particular, course includes three compulsory exercises on additive manufacturing of polymers (with focus on materials extrusions or FDM) using Simplify software, design and job preparation for metal AM (with focus on powder bed fusion – laser beam) using Magics software and simulation for AM (with focus on powder bed fusion – laser beam) using Simufact software.

5. Lecturers, course examiner, course co-ordinator and tutors

Examiner:

Professor Eduard Hryha, Industrial and Materials Science, Chalmers

hryha@chalmers.se - EH

Lecturers:

Professor Eduard Hryha, Industrial and Materials Science, Chalmers

hryha@chalmers.se – EH

 

Practical/computer exercises, tutors:

• Ahmed Fardan Jabir Hussain: fardan@chalmers.se - AF
• Rasmus Gunnerek: gunnerek@chalmers.se - RG
• Plinio Fernandes Borges Silva: plinio@chalmers.se - PF
• Satya Chaitanya Vaddamanu: satyac@chalmers.se - SC
• Erika Tuneskog: tuneskog@chalmers.se - ET

Course administrator:

• Satya Chaitanya Vaddamanu: satyac@chalmers.se - SC

Student reception of department (mainly for exam and general enquiries):

• Hanije Safakar: hanije@chalmers.se

 

6. Student representatives

 

 

 

 

 

7. Literature and course material

Reference course book is: Additive Manufacturing Technologies by Ian Gibson, see https://link-springer-com.proxy.lib.chalmers.se/book/10.1007/978-3-030-56127-7   The reference book for the Design for AM: A Practical Guide to Design for Additive Manufacturing by Olaf Diegel, Axel Nordin and Damien Motte, see: https://link-springer-com.proxy.lib.chalmers.se/book/10.1007%2F978-981-13-8281-9.

The course contents will be based on lecture handouts and supplementary material as well as partly on chapters from these books. All sources are available as e-books via Chalmers library. The book by Gibson can be bought as paper-back at reasonable cost at Chalmers. Problem solving examples are defined separately and not necessarily taken from reference course book.

Lecture notes (Powerpoint presentations) will be published on homepage for the course. The software for AM pre-processing Simplify 3D (for polymer printing) and Magics (for powder-bed based AM) as well as simulation software Simufact are installed in MT10 and can be accesses physically or remotely for computer exercises and project work used during the course. The softwares are licensed for educational purposes only and you are not allowed to be used for commercial purpose.

8. Examination

The examination is based on the combination of final written/oral exam and project work including final oral presentation and report. The grading is based on the total score of the final exam (max 50p) and the project assignment (max 10p). The total score is 60p. The grading will be based on following limits:

Grade 3 > 40% = 24p

Grade 4 > 60% = 36p

Grade 5 > 80% = 48p

The project assignment can give 2, 4, 6p, 8p or 10p related to the quality of the report and the oral presentation. Due date for handing the final report is the day before the project presentation.

The exam takes place on March 15-th, 2024, between 12.30 and 17.00. Details about exam will be communicated during the course.

All re-exams will take place in form of oral exams and has to be booked with examiner during specific re-examination periods.

9. Project assignment

Project assignment for each group is defined together with the lecturers and tutors (Eduard, Fardan, Rasmus and Plinio) and is focused on either proposal of interest or specific components for electric bike that is intended to be 3D printed as a result of the course. Project groups can also suggest their own proposal that, however, must be approved before starting the work.

Important issues

Each group with maximum 6 members

One report per group, max 5 pages without attachments

Oral presentation in seminar form with the whole class

Work content

• Application review, based on literature survey and state-of-the-art to justify why AM is suitable for the intended product/design;
• Materials/process selection;
• Assessment of potential product performance and need for post-AM processing;
• Components design by CAD and preparation for AM via Simplify 3D and/or Magics to buildable product;
• Components build using infrastructure provided (focus on prototype printing in polymer);
• Critical review of possible constraints with respect to performance, cost, etc.

 

During the course, all the groups should print components using polymer/composite printers. Suitable components for metal additive manufacturing, after approval, may be selected as demonstrator to be built using variety of metal AM technologies.

 

10. Specific practicals

 

Laboration – polymer printing. After having prepared you own design you are supposed to do a printing using polymer printers. This lab is compulsory and booked on individual group base with the respective groups tutors.

 

11. Schedule (preliminary)

Date	Time	Lecture/exercise	Lecturer	Place	Links
2024-01-16	13:15-15.00	Introduction to AM – basic principles and overall state-of-the-art	EH	HC2
2024-01-16	15:15-17.00	AM applications and future perspectives		HC2
2024-01-18	13:15-15.00	Overview of AM technologies and their capabilities/limitations – Part I		HC2
2024-01-18	15:15-17.00	Overview of AM technologies and their capabilities/limitations – Part II		HC2
2024-01-19	13:15-15.00	Overview of AM technologies and their capabilities/limitations – Part III		HC2
2024-01-23	13:15-15.00	Overview of AM technologies and their capabilities/limitations – Part IV		HC2
2024-01-23	15:15-17.00	Introduction to Computer Exercises: -       Computer Exercise I: Practical training on Simplify - RG -       Computer Exercise II: Practical training on Magics – AF -       Computer Exercise III . Simulation of AM process by Simufact - PF	RG, AF, PF	HC2
2024-01-25	13.15-15.00	Overview of AM technologies and their capabilities/limitations – Part V	EH	HC2
2024-01-25	15.15-17.00	Overview of AM technologies and their capabilities/limitations – Part VI	EH	HC2
2024-01-26	13.15-15.00	Design for powder-based metal AM - overview	EH	HC2
2024-01-30	13:15-14.00	lab tour and project discussion - Group 1-3	EH, RG, AF, PF, SC	HC2
2024-01-30	14:15-15.00	lab tour and project discussion - Group 4-6	EH, RG, AF, PF, SC	HC2
2024-01-30	15:15-16.00	lab tour and project discussion - Group 7-9	EH, RG, AF, PF, SC	HC2
2024-01-30	16:15-17.00	lab tour and project discussion - Group 10-12	EH, RG, AF, PF, SC	HC2
2024-02-01	13:15-15.00	Materials for AM	EH	HC2
2024-02-01	15:15-17.00	Properties of AM materials	EH	HC2
2024-02-02	13:15-15.00	Q&A: computer exercises Project tutoring	RG, AF, PF	MT11&MT12/Zoom/ Chalmers
2024-02-08	13:15-15.00	Post-AM processing	EH	HC2
2024-02-08	15:15-17.00	Project supervision	EH, RG, AF, PF	HC2
2024-02-09	13:15-15.00	Q&A: computer exercises Project tutoring	RG, AF, PF	MT11&MT12/Zoom/ Chalmers
2024-02-13	13:15-15.00	Guest lecture by Arcam, Electron Beam Melting, Mattias Fager, Arcam EBM	Mattias Fager: mattias.fager@GE.com	HC2
2024-02-13	15:15-17.00	Guest lecture: More than 30 years in AM of metals – overview on DMLS R&D at EOS, Juha Kotila, EOS Finland Oy	Juha Kotila, juha.kotila@eos.info	HC2/Zoom
2024-02-16	13:15-15.00	Guest Lecture: Powder Production, Prof. Sven Bengtsson, Höganäs AB	Prof. Sven Bengtsson, Sven.Bengtsson@hoganas.com	HC2
2024-02-20	13:15-15.00	Post-AM processing	EH	HC2
2024-02-20	15:15-17.00	Selection of AM processes I	EH	HC2
2024-02-22	13:15-15.00	Guest Lecture: Binder jetting technology for production of high precision metal components, Mats Nilsson, Digital Metal AB	Mats Nilsson, Mats Nilsson mats.nilsson@markforged.com	HC2
2024-02-22	15:15-15.00	Selection of AM processes II	EH, RG, AF, PF	HC2
2024-02-23	13:15-14.00	Guest lecture: “Industrialization of AM et Siemens”, Nicklas Johansson, Siemens Energy, Finspång, Sweden	Dr. Nicklas Johansson: nicklas.p.johansson@siemens-energy.com	HC2
024-02-23	14.15-15.00	Guest lecture: “Additive manufacturing of materials for gas turbine applications”, Prof. Håkan Brodin, Siemens Energy, Finspång, Sweden	Prof. Håkan Brodin: hakan.brodin@siemens-energy.com	HC2
2024-02-27	13:15-14.00	Guest Lecture: Additive Manufacturing by LASER-based DED, Dr Thomas Elcrin, AddUp	Thomas Elcrin, thomas.elcrin@addupsolutions.com	HC2/Zoom	https://chalmers.zoom.us/j/69284429483 Password: 735056
2024-02-27	14:15-15.00	Guest lecture: “Surface finishing solutions for Metal Additive Manufacturing”, Dr Agustin Diaz, REM Solutions	Dr Agustin Diaz, adiaz@REMCHEM.COM	HC2/Zoom	https://chalmers.zoom.us/j/67049383503 Password: 958911
2024-02-27	15:15-17.00	Project supervision	EH, RG, AF, PF	HC2
2024-02-29	13:15-15.00	Seminar – project presentations	EH, RG, AF, PF	HC2
2024-02-29	15:15-17.00	Seminar – project presentations	EH, RG, AF, PF	HC2
2024-03-01	13:15-15.00	Problem solving/previous exams	EH	HC2
2024-03-05	13:15-17.00	Tour to RISE AM Centre	RG, AF, PF, ET, SC	RISE, Mölndal
2024-03-07	13:15-17.00	Tour to Arcam	RG, AF, PF, ET, SC	Arcam, Mölnlycke
2024-03-08	13:15-15.00	Additional practical event in MT10	RG, AF, PF	MT11&MT12

 

15/3                                    13.00-17.00 EXAM – Chalmers Johanneberg