This course will teach some practical guidance on how to design parts to gain the maximum benefit from what AM can offer. The course will involve a lot of hands-on project work in which you will design parts for 3D printing, print them, and do all the required post-processing for the parts. This course will teach you how to design for AM and to use the many software technologies that are needed to make part lighter, better and more consistent. This software includes topology optimisation and lattice structures. The hands-on projects will allow you to use the CAD skills you have been taught throughout your engineering degree, and to apply the theory and design skills you are taught.
Topics covered include:
• Recent AM growth trends and developments around the world.
• Benefits of AM, in the context of DfAM, how AM is being applied, and how certain parts can be designed for AM.
• When to use AM and when not to use AM
• The thought processes behind design for AM
• Examining the complete AM process chain, from CAD part creation, to part production. This allows students to see how an understanding of the entire process chain helps them to design better AM parts.
• Description of AM technologies, with advantages/ disadvantages/ applications of each,
• File formats, and working with STL manipulation software such as Magics, Meshmixer, etc.
• Examining AM from an economic point of view for both direct part production and tooling applications. Understanding what you, as a design engineer, can do to minimise the costs.
• Specific issues and design guidelines surrounding polymer AM (FDM, SLS, SLA, etc.), including post-processing, etc.
• Characteristics of metal powders, and how they are made
• Metallurgical properties of metal AM parts
• Specific issues and guidelines around designing for metal AM, including anisotropy, process constraints, general guidelines relating to wall thicknesses, hole sizes, tolerances, angles, etc. Metal AM post-processing and material properties.
• Designing topology optimized parts for additive manufacturing. Basic thought process and methodology behind TO software.
• Approaches to designing lightweight lattice structures. Exploring 3 different common lattice methods.
• The thought process behind part consolidation
• Looking at AM beyond direct part production: Injection molding tools, sheet-metal forming tools, extrusion tools, jigs and fixtures, etc.
• Adding mounting fixtures to parts to ease mounting on CNC machines for more efficient post-processing.
• Using design automation software to add value to AM products. General nTopology intro.
• Mass-customisation
• Looking at where AM and design software tools are headed in the near future, and the implications this will have on DfAM.