JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY HYDERABAD

Prerequisites

Basics of Manufacturing, Basic knowledge in Calculus, Physics, Thermodynamics,

and Chemistry

Course Objectives

The objective of the Course is to study methods used in additive manufacturing,

theories governing the additive manufacturing, give information on materials, explain relations between materials to be processed and methods of additive manufacturing with introduction to common machines used for the technology and show applications and business opportunities with future directions.

Course outcomes: At the end of the course, the student will be able to

• Understand the fundamentals for additive manufacturing and how it is different.
• understand about various types of liquid based and solid based AM technologies.
• understand about various types of powder-based, laser based and rapid tooling AM technologies.
• Understand the various types of Pre-processing, processing, post-processing errors in AM. Also to know the various types of data formats and software’s used in AM.
• Know the various applications of AM in design analysis, aerospace, automotive, biomedical and other fields.

UNIT - I

Introduction: Prototyping fundamentals: Need for time compression in product development, Need for Additive Manufacturing, Historical development, Fundamentals of Additive Manufacturing, AM Process Chain, Advantages and Limitations of AM, Commonly used Terms, Classification of AM process, Fundamental Automated Processes: Distinction between AM and CNC, other related technologies.

UNIT - II

Liquid-based AM Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Poly jet: Process, Principle, working principle, Applications, Advantages and Disadvantages, Case studies. Micro fabrication. Solid-based AM Systems: Laminated Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused Deposition Modeling (FDM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Multi-Jet Modelling (MJM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies.

UNIT - III

Powder Based AM Systems: Selective laser sintering (SLS): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Three-dimensional Printing (3DP): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Laser Engineered Net Shaping (LENS): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Electron Beam Melting (EBM): Models

and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Rapid Tooling: Introduction to Rapid Tooling (RT), Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification: Indirect Rapid Tooling Methods: Arc Spray Metal Deposition, Investment Casting, Sand Casting, 3D Keltool process. Direct Rapid Tooling: Direct AIM, LOM Tools, DTM Rapid Tool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP.

UNIT - IV

AM Data Formats: Reengineering for Digital Representation, STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Mesh Refining by Sub division Techniques. AM Software’s: Need for AM software, Features of various AM software’s like Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor, Surgi Guide, 3-matic, Simplant, Mesh Lab.

UNIT - V

AM Applications: Application – Material Relationship, Application in Design, Application in Engineering, Analysis and Planning, Aerospace Industry, Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning and simulation of complex surgery, Customized Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and Anthropology, Visualization of Biomolecules. Web Based Rapid Prototyping Systems

TEXT BOOK:

• 1. Rapid prototyping: Principles and Applications by Chua C.K., Leong K.F. and LIM C.S, World Scientific publications, Third Edition, 2010.

REFERENCE BOOKS:

• 1. Rapid Manufacturing by D.T. Pham and S.S. Dimov, Springer, 2001.
• 2. Wholers Report 2000 by Terry Wohlers, Wohlers Associates, 2000.
• 3. Rapid Prototyping & Engineering Applications by Frank W.Liou, CRC Press, Taylor & Francis Group, 2011. M. TECH. I Year I Sem. (AMS)