LEARNING OUTCOMES

AM is a technique that enables the creation of complex 3D objects, thus widely expanding the design space with respect to the traditional subtractive manufacturing. This technology has in recent years entered diverse applications, such as medical, aerospace and automotive due to innovations in materials and processing technologies. A proper use of AM also requires the knowledge of software tools capable of handling the geometric complexities of designed components, and numerical tools for materials and components design, structural analyses and optimization.

OUTCOMES: To provide, by means of theoretical concepts and project-based learning, the knowledge of those processes and tools required for product re-engineering by means of modern Additive Manufacturing (AM) techniques. The course is composed of lectures and lab exercises covering methods for 3D scanning of existing parts/assemblies, structural optimization, and subsequent AM of parts/components by Fused Filament Fabrication (FFF). Practical applications are envisaged in the area of Mechatronic Engineering, Marine Industry, and Yacht Design

AIMS AND LEARNING OUTCOMES

Introduction to general aspects of Reverse Engineering and Additive Manufacturing 

• 3D scanners
• AM materials
• Design tools for AM

In-depth study of some particular interesting topics for the mechatronic engineers and the yacht designers by means of a group project.

PREREQUISITES

None

TEACHING METHODS

The course is structured into equally subdivided theoretical and practical lectures (Laboratories).

SYLLABUS/CONTENT

Additive Manufacturing Technologies

• Overview of the main state-of-the-art AM technologies. Materials used in AM.

Part A: Reverse Engineering

• Hardware and Software tools for 3D scanning of existing parts/assemblies:
  • Practical laboratory demonstration of 3D scanners based on laser-camera triangulation.
  • Software tools for the preprocessing of 3D scanned data and for the generation of polygonal models.
  • Reconstruction of 3D CAD models from scanned data by means of both surface modelling and feature-based parametric modelling.
  • Dimensional analysis from scanned data, preparation of 3D digital models for 3D printing.

Part B: Materials Modeling and Morphological Optimization

• Design for Additive Manufacturing (DfAM):
  • DfAM Strategic Design Considerations & General Guidelines.
  • Materials design.
  • Numerical modeling of polymeric and composite materials.
  • Computational Tools for Design Analysis and Optimization of AM Parts (Topology Optimization, Parametric or Size Optimization).
  • Guidelines for Part Consolidation.
  • Design for Polymeric AM via FFF.
  • Laboratory demonstration of 3D printers based on FFF technologies.

Part C: Case Study

Project work consisting of 3D-scanning, 3D-modeling, 3D-printing, and assessment of a simple structural/mechanical component selected as a case study. Particular attention will be paid to the specific needs of both Mechanical and Nautical Engineering students.

RECOMMENDED READING/BIBLIOGRAPHY

Compulsory Textbooks

• Lecture notes and video tutorials provided by the lecturer (available on AulaWeb).

Reference Textbooks

• O. Diegel, A. Nordin, D. Motte, A Practical Guide to Design for Additive Manufacturing, Springer, 2020
• Lorna J. Gibson, Michael F. Ashby. Cellular Solids: Structure and Properties. Cambridge University Press, 1999
• N. E. Dowling, Mechanical Behavior of Materials, Editore: Prentice Hall, 2013