OVERVIEW

The program is divided into three parts, which meet the need to: 1) offer a global view of methods and tools for reverse engineering (3D scanning); 2) provide an overview of Additive Manifacturing Technologies along with methods for Material modelling; 3) present innovative tools for Design for Additive Manufacturing and related structural optimization techniques. The course includes visits to industries, seminars and conferences.

AIMS AND CONTENT

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

TEACHERS AND EXAM BOARD

Exam Board

MASSIMILIANO AVALLE (President)

GIOVANNI BERSELLI (President)

FLAVIA LIBONATI (President)

MATTIA FRASCIO

LESSONS

LESSONS START

https://corsi.unige.it/9269/p/studenti-orario

Class schedule

The timetable for this course is available here: Portale EasyAcademy

EXAMS

EXAM DESCRIPTION

The exam will consist in a Group project followed by an oral evaluation focusing on project discussion  and knowledge assessment of theoretical concepts.

The course is structured into equally subdivided theoretical and practical classes. The examination consists in an oral test composed of two parts:

1. Project evaluation. The industrial project developed by the students throughout the course will be critically discussed. Part 1 is worth 50% of the overall grade.
2. Knowledge assessment of theoretical concepts, involving a discussion of the engineering notions presented during the lectures. Part 2 is worth 50% of the overall grade.

The final grade is computed as the mean value of the marks obtained in Part 1 and Part 2.

ASSESSMENT METHODS

The evaluation of the project will allow to assess the students' abilities to employ reverse engineering and design-for-additive tools, in the correct and effective development of components made with these technologies. The oral exam aims to ascertain the knowledge and understanding of software tools, materials and three-dimensional scanning techniques, studied during the course.

Exam schedule

FURTHER INFORMATION

Pre-requisites: none