Additive Manufacturing - 2024 entry

This module is dedicated to additive manufacturing, focusing on parts that are fabricated through additive processes (powder or filament – metallics, polymer or composites) versus the conventional, subtractive methods. As we approach a time where resources scarcity and clean/carbon neutral manufacturing technologies are amongst the key business drivers in many engineering sectors, this module aims to introduce you to the digital manufacturing processes, materials, design and applications.

The syllabus will provide you with in-depth knowledge of additive manufacturing processes for metallics, polymers and composites, from principles of operation to fundamentals of material processing including rheology (powder and polymer melt), sintering mechanisms and models, crystallization characteristics. Properties and green credentials of the technology will also be discussed.

The module aims to give you an understanding of the variety of additive manufacturing processes available across metals, polymers and ceramics with in-depth focus and fundamental knowledge on the powder bed technologies (polymeric and metallic) used nowadays for production by industry. The relationship structure-process-property will be discussed through research led examples. Advantages and disadvantages of each process will be introduced and compared with conventional manufacturing processes. The green credentials of AM technologies will be discussed in terms of light weighting, recyclability of powders, and supply chain.

The module also includes a demonstration of various technologies or specialist characterisation equipment in the Centre for Additive Layer Manufacturing (CALM), as well as direct interaction with the CALM research team in support of the coursework. In the context of AM research, CALM has unique facilities amongst the R&D centres in UK or Europe.

1. Understand characteristics of particular AM equipment, processes, or products, with extensive analysis of a wide range of engineering materials and components SM3m, SM4m, EA5m, D5m, ET2m, ET4m, EP2
2. Apply the developing technologies to own specialisation EP1m, EP2m, EP3m
3. Create new designs based on AM guidelines EA5m, D2m, D7m, EP3m, D8m
4. Ability to use fundamental knowledge to investigate new and emerging technologies
5. Apply the design process to new products, including cost drivers, and evaluate outcomes
6. Evaluate the commercial, economic and social context of the manufacturing processes
7. IUnderstand the requirements for the manufacturing activities, create sustainable developments and apply quantitative analysis where appropriate EP1m
8. Apply and integrate knowledge and understanding of other engineering disciplines to support study of own engineering discipline and the ability to evaluate them critically and to apply them effectively
9. Obtain information independently and evaluate it critically
10. Accurately and independently summarise research articles from peer-reviewed journals, without guidance.

1: Type of AM technologies – categories per material (powder bed, powder feed, filament deposition), method of operation (e.g. laser, filament, wire);

2: Design – AM comparison with conventional processes (e.g. injection moulding);

3: Polymer/composite/nanocomposites specific systems – principle of operations;

4: Metallic specific systems– principle of operations;

5: Powder bed processes – powder rheology -theory, crystallisation and coalescence – theory & models;

6: Recyclability of powders – the influence of process on powders – analysis;

7: Demonstration – CALM lab;

8: Use of FabLab facilities.

Reassessment will be by a single written exam only worth 100% of the module. For deferred candidates, the mark will be uncapped. For referred candidates, the mark will be capped at 50%.

Set of research papers, as introduced, presented, or referenced in the lectures

Reading list for this module: