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| Credit- Degree applicable | | Effective Quarter: Fall 2018 | I. Catalog Information
| DMT 54 | 3D Printing/Additive Manufacturing: Theory and Practice | 4 Unit(s) |
| | Requisites: Prerequisite: DMT 53. Hours: Lec Hrs: 48.00
Out of Class Hrs: 96.00
Total Student Learning Hrs: 144.00 Description: A focus on design considerations and rapid prototyping applications of Additive Manufacturing (AM), commonly known as 3D Printing. Using a combination of lecture and hands-on projects, students will explore the design and material considerations within AM and will configure AM systems and build prototypes and functional parts. Guest lecturers from the AM industry will provide key insights and best practices across a wide array of AM technologies. Students are expected to have a fundamental understanding of at least one parametric modeling CAD system to produce functional designs. |
| Student Learning Outcome Statements (SLO)
| | | • Student Learning Outcome: Apply knowledge of advanced Additive Manufacturing/3D Printing to analyze, compare, explain and utilize the primary production processes for prototyping and fabricating new mechanical designs and tools for industry implementation. |
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II. Course Objectives | A. | Recognize the advantages and limitations of 3D Printing/Additive Manufacturing technologies in developing new engineering systems and identifying emerging opportunities in developing products for mass customization products and processes. |
| B. | Explore design processing parameters for the Additive Manufacturing process solution chain with available systems and software. |
| C. | Utilize best practices in design intent and implement principles of “Design for Additive Manufacturing” DFAM. |
| D. | Explain the principles of Material selection options for AM design considerations; Tensile strength / Heat Deflection / ISO certification considerations. |
| E. | Compare prototyping and product cycle considerations in the Additive Manufacturing process. |
III. Essential Student Materials IV. Essential College Facilities | | Additive Manufacturing/3D Printing, CAD computer laboratory |
V. Expanded Description: Content and Form | A. | Recognize the advantages and limitations of 3D Printing/Additive Manufacturing technologies in developing new engineering systems and identifying emerging opportunities in developing products for mass customization products and processes. |
| 1. | Fused Deposition Modeling FDM or Fused filament fabrication FFF |
| 2. | Stereolithography (SLA) |
| 3. | Metal powder bed fusion technology (DMLS) |
| 4. | Selective Laser Sintering (SLS) |
| 5. | Material Jetting (PolyJet) |
| 6. | Digital Light Processing (DLP and CLIP) |
| B. | Explore design processing parameters for the Additive Manufacturing process solution chain with available systems and software. |
| 1. | Conceptualization and CAD development. |
| 2. | Conversion STL/AMF and object slicing function / algorithm processes. |
| 3. | Translate to AM System and STL file manipulation and object slicing function / algorithm processes. |
| 4. | AM system preparation and software function. |
| 5. | Post-Processing options and techniques |
| C. | Utilize best practices in design intent and implement principles of “Design for Additive Manufacturing” DFAM. |
| 1. | Optimize for new Freeform geometry creation, AM’s layer-by-layer fabrication approach. |
| 2. | Identify, explain, and prioritize some of the important design challenges in various AM processes. |
| 3. | Considerations of AM tolerancing for various part, assemble, geometry and surface features (e.g.,
through holes, snap-fits, living hinges, lattice structures etc.) |
| 4. | Form Fit and Function capabilities and limits offered by prototyping in new AM engineering design. |
| c. | ISO certification considerations. |
| 5. | Utilize topology optimization directly for part design. |
| D. | Explain the principles of Material selection options for AM design considerations; Tensile strength / Heat Deflection / ISO certification considerations. |
| 2. | Acrylonitrile butadiene styrene (ABS) |
| a. | Continues or chopped Carbon Fiber inlay |
| c. | High Strength, High Temperature (HSHT) Fiberglass |
| 6. | Durable, Flexible or High Temp SLA Resins |
| E. | Compare prototyping and product cycle considerations in the Additive Manufacturing process. |
| 1. | Experiment and learn during the design process. |
| 2. | Testing and proofing of design ideas and concepts. |
| 3. | Communicate and interact among design teams. |
| 4. | Synthesis and interrogation of the entire product concept. |
| 5. | Scheduling and marketing considerations. |
VI. Assignments | A. | Reading from textbook, videos and research projects. |
| B. | In class projects to identify and understand various materials strength, limitations and functional processes for available 3D Printing technology. |
| C. | Under the supervision of the instructor develop functional CAD projects, within assigned 3D Printing/Additive Manufacturing parameters, for final project. |
VII. Methods of Instruction | | Lecture and visual aids
In-class exploration of Internet sites
Quiz and examination review performed in class
Homework and extended projects
Guest speakers
Collaborative learning and small group exercises
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VIII. Methods of Evaluating Objectives | A. | Practical examinations and written report to test the student understating of 3D Printing/Additive Manufacturing technology and design methodologies as presented in class, through research and reading assignments. |
| B. | Mid-term Examination covering assigned video lectures, textbook reading, assigned research and basic design prototyping projects. Exam will be evaluated on completeness of design intent, utilization of optimized 3D Printing perimeters; as well as form, fit and function. |
| C. | Evaluation of final student design project; with consideration to proper utilization of available 3D Printing and CAD technology. |
IX. Texts and Supporting References | A. | Examples of Primary Texts and References |
| 1. | Ian Gibson, David Rosen, Brent Stucker "Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing" 2nd Edition Springer, 2015 |
| B. | Examples of Supporting Texts and References |
| 1. | Amit Bandyopadhyay, Susmita Bose "Additive Manufacturing" CRC Press, 2015 |
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