Additive Manufacturing

The aim of this course is to equip students with knowledge and skills in the field of process design based on additive manufacturing (3D printing), and its application to both metallic and polymer materials. The course develops competencies in the design, analysis, and construction of modern manufacturing systems, as well as the application of topology optimization and generative design to achieve optimal structural solutions.

Upon successful completion of this course, students will be able to: • Identify the fundamental differences between additive manufacturing methods and other processing technologies • Distinguish between various additive manufacturing processes • Compare different additive manufacturing methods • Analyze the applicability of additive manufacturing • Select an appropriate type of additive manufacturing and define processing parameters based on structural load and intended function • Generate a computer model suitable for additive manufacturing through design, data exchange, or 3D scanning • Apply generative design approaches inspired by natural growth principles • Optimize part geometry according to the constraints of additive manufacturing technologies • Prepare models for manufacturing • Design and analyze a manufacturing system intended for additive production.

Classification of technologies; Basic concepts and the importance of Additive Manufacturing; Classification of additive manufacturing technologies; Additive manufacturing processes; Applications (production of prototypes, functional parts, and tools); Techniques for creating 3D models using CAD tools and 3D scanning; Natural building methods and generative design approaches; Practical examples, future directions of development in Additive Manufacturing.

Laboratory exercises on equipment where students become familiar with practically implemented manufacturing systems for additive production. Introduction to the process of manufacturing functional parts. Computer simulations: geometry optimization, definition of manufacturing technology, design of subsystems corresponding to the selected type of additive technology. Workshops: part scanning and processing in CAD software. Rapid prototyping and rapid tooling and fixture production. Testing of mechanical properties of parts produced by additive manufacturing.

Defined by the study program / module curriculum.

FFF 3D printers: Creality Ender 3, Creality Ender 5S1, Builder Extreme 3000 PRO, Bambulab A1, Bambulab X1C, Snapmaker A350; mSLA 3D printers: Creality LD-002R, Anycubic Photon; 3D scanner Creality CR-Scan Raptor; Filament extruder for 3D printer; 3D pen; Lectures in electronic form; Instructions for performing exercises in the laboratory; Instructions for project design; CAx workstations with appropriate software packages.

Total assigned hours: 90

New material: 20
Elaboration and examples (recapitulation): 10

Auditory exercises: 5
Laboratory exercises: 20
Calculation tasks: 0
Seminar paper: 0
Project: 10
Consultations: 0
Discussion/workshop: 10
Research study work: 0

Review and grading of calculation tasks: 0
Review and grading of lab reports: 2
Review and grading of seminar papers: 0
Review and grading of the project: 4
Test: 0
Test: 4
Final exam: 5

Activity during lectures: 5
Test/test: 30
Laboratory practice: 15
Calculation tasks: 0
Seminar paper: 0
Project: 20
Final exam: 30
Requirement for taking the exam (required number of points): 40

Gibson I, Rosen W.D, Stucker B, Additive Manufacturing Technologies - Rapid Prototyping to Direct Digital Manufacturing, Springer, 2010.; Gebhardt A, Heotter J.S, Additive Manufacturing, 3D Printing for Prototyping and Manufacturing, Hanser Gardner Publications, 2016.; Stritesky О, Prusa Ј, Bach М, Basics of 3D Printing with Josef Prusa, Prusa REsearch, Prague 2019.