Additive Layer Manufacturing

Course content

After completing the module, students can select the most appropriate 3D printing technology and respective materials to manufacture parts by 3D printing. Furthermore, they are able to plan and execute the whole process chain, starting with CAD model and finishing with real, ready-to-use parts. They can select appropriate post-processing steps, surface preparation and surface treatments. Student are capable to steer the part-designing process to increase printability success, reduce material waste and post-processing time. With the taught knowledge of Additive Manufacturing and topology optimization, students are able to create sophisticated, topology-optimized models or re-design existing ones.

Materials for ALM:

• Polymers, metals, ceramics, paper, powders, thermoplastics, ALM manufacturing processes in direct layer build-up
• Polymerisation, polymer jetting
• Sintering and melting
• Extrusion
• Powder binder processes
• Layer Manufacturing Modelling
• Basics
• FEM
• Basics of optimisation algorithms
• Basics of structural optimisation, especially topology optimisation Modelling
• Application of different optimisation algorithms in topology optimisation
• Approaches for the consideration of direction-dependent material parameters within form finding Design of components to be manufactured using ALM methods with 3D CAD data generation Design of simple components
• Tensile specimens for determining characteristic values
• Production and testing of a simple component in competition with other students