September 5-11 Welcome. Introduce the course objectives and syllabus. Familiarize the students with the history and development of 3D printing technology. Interactive discussion on 3D printing. Team building for group assignments and presentations. Lecture: Course introduction History of technological advancements Class discussion Team building Literature review assignment and scheduling Chap. 1 and Chap. 2.9, 2.10, 2.11. September 12-18 Introduction to 3D printing. Introduce the 3D printing process including computer aided design (CAD), the interface and basic tools available for 3D printing (software requirements, compatible file formats, etc.). Students to finalize their teams. LAB: Hands-on training on how to use the printers. 3D printing of demos. Lecture: Introduction to 3D printing Lab: 3D printing demo designs. RA: Chap. 1 Students to finalize teams Quiz 1 September 19-25 Software for Additive Manufacturing. Preparation of Computer Design (CAD) models, creating STL files from CAD images, image slicing, file manipulation, and problems with files. LAB: Design and printing exercises. Lecture: Introduction to 3D printing (design, slicing, and printing) Lab: Design and printing exercises. Class Students were given journal articles to review and present to class (2 per class from Week 4 to Week 13. 10 min each presentation followed by class discussion).
September 26-October 2 3D printing technology. Overview of 3D printing methods and selection of ink materials (materials selection) for each method. Summary of limitations and advantages of each technique for specific application. (Class presentations followed by discussion) LAB: Design Challenge 1. Students will be given a design challenge, during which they will come up with a design, and 3d print a functional component. Students are expected to write a short report about their design. Lecture: 3D printing methods. Ink formulations. Materials selection for ink formulations. Class presentations. Lab: Design Challenge 1. Class presentations Chap. 3 October 3-9 Vat Photopolymerization printing. Printing technology, basics, materials, applications and limitations. LAB: Final Design Project assignment, and evaluation of Design Challenge 1. In lab demonstration of stereo lithography printing process. Lecture: Vat Photopolymerization Lab: Final Design Project Stereolithography printing Class Design Challenge report due. Quiz 2 October 10-16 Powder-based printing. Printing technology, basics, materials, applications and limitations. LAB: Design Challenge 2. In lab demonstration of powder-based printing process. Lecture: Powder based printing Lab: Design Challenge 2 Powder based printing Class presentations October 17-23 Extrusion-based printing. Printing technology, basics, materials, applications and limitations. LAB: Design Challenge 2. In lab demonstration of powder-based printing process. Lecture: Extrusion based printing Lab: Design Challenge 2 Powder based printing Class presentations
Nov 21-27 3D printing industry. Students will be familiarized with the major players in 3D printing industry, and global effects of 3D printing. LAB: Evaluation of Design Challenge 3. Teams working on their final Design Project. Lecture: 3D printing industry Global effects Class presentations Lab: Final Design Project. Class presentations Student assays due Quiz 5. Nov 28-4 Team Presentations and Assessments. Teams will give a short (10 min) lay presentation on their design: Why they chose the design? What were the main obstacles in their design? etc. Final Design Project Presentations Team presentations Dec 5-11 Team Presentations and Assessments. Teams will give a short (10 min) presentation on their design: Why they chose the design? What were the main obstacles in their design? etc. Final Design Project Presentations Team presentations Team’s Report due. Assignments Each student will be required to present one paper to the class. Student presentations will start in Week 3. This presentation will be followed by class discussions related to the presentation. All students will be expected to read the paper beforehand and be prepared to discuss the paper. In addition to the paper presentations, students will be expected to form teams (Week 1) and will develop simple designs, in each lab session, based upon the examples provided by the instructor for FDM type 3D printing (Design Challenge). In addition, each team will be given a Final Design Project, and will be required to come up with a simple but creative design (a tool or a device, TBD). Each team will be required to prepare a written report and present their design process by the end of the course. Prerequisites Junior standing or higher. Required Textbook Additive Manufacturing Technologies – 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, by Ian Gibson, David Rosen, and Brent Stucker, Second Edition, Springer, New York. (Will be available in the bookstore) Grading Criteria Quizzes 10%