Material Extrusion (FDM, FFF): Material flow mechanics through a nozzle. Printing of polymers, biopolymers and polymer matrix composites. 3D printer configuration and motion control. Robotic arms as 3D printers. Process parameters, 3D printer parameters and connection to part quality.
Selective laser sintering and melting (SLS/SLM): Laser-matter interaction during sintering and melting. Melt pool, solidification, transformations of metallic materials. Sintering of non-metallic materials. SLS/SLM machines: configuration and control based on melt pool characteristics. Process parameters, machine parameters and connection to part quality.
VAT polymerisation (SLA): Resin polymerisation using monochromatic light and other sources. SLA machines and control of layer thickness. Process parameters, printing parameters and connection to part quality.
Other methods (direct energy deposition-DED, material jetting, binder jetting, sheet lamination): Physics of material joining. Functional principles of pertinent machines. Process parameters, constraints and part quality.
Process selection – case studies: Comparison to conventional processes and to the rest of AM processes. Post-processing. Survey of the range of materials that can be processed in general applications. Special applications of materials and methods in biomechanics, biomedicine, aerodynamics. Futureapplicationsandnewmaterialsoutlook.
CAD/CAM Interfaces: Layer design, path design, pertinent constraints and optimization. CAM systems and slicers for layer and path definition. Relevant standards (STL, AMF etc).
