Metal Additive Manufacturing Crash Course
This intensive course spans about 5 hours for 1 day.
Saturday, December, 29th
Time: 09:30 AM TO 02:30 PM
Location: MPU hall, Ground floor, CHEP building, Faculty of Engineering, ASU
Saturday, December, 29th
Time: 09:30 AM TO 02:30 PM
Location: MPU hall, Ground floor, CHEP building, Faculty of Engineering, ASU
Course Description:
3D printing is a rapidly growing manufacturing approach in which digital 3D models can be transformed into a physical object. This is achieved by stacking thin layers of the material to gradually build the desired geometry. In the recent years, products and objects made from high melting point metals and alloys, advanced engineering plastics and even biological tissues were successfully produced. The objective of this course is to introduce the participants to the 3D printing technologies and their applications in a wide variety of fields. The course consists of lectures, practical sessions on 3D printing machines, and case studies taken from different industries and applications
3D printing is a rapidly growing manufacturing approach in which digital 3D models can be transformed into a physical object. This is achieved by stacking thin layers of the material to gradually build the desired geometry. In the recent years, products and objects made from high melting point metals and alloys, advanced engineering plastics and even biological tissues were successfully produced. The objective of this course is to introduce the participants to the 3D printing technologies and their applications in a wide variety of fields. The course consists of lectures, practical sessions on 3D printing machines, and case studies taken from different industries and applications
09:30 AM - 12:00 PM Introduction to 3D printing and metal additive manufacturing technologies: the techniques, advantages and limitations.
Lecture Content:
Topics' List:
1. Classification of manufacturing techniques (additive, subtractive, consolidation, conservation), highlighting process economics.
2. Definition of 3D printing technologies: CAD data, STL files, slicing, etc…
3. Overview of 3D printing classes, typical materials, feedstock material (filaments, powders, wires, etc…)
4. Description of the most common plastics 3D printing technologies:
a. Fused deposition modelling d. Material/Binder jetting 3D printing
b. Stereolithography e. Other techniques: laminated object manufacturing, solid ground curing, etc…
c. Selective laser sintering
5. 3D printing specifics: support structure, overhanging features, and post processing.
6. Typical applications for plastics 3D printing
a. Automotive c. Archaeology/conservation
b. Medical d. Other applications: casting, electronic housing, prototyping, etc…
7. Description of the most common metal 3D printing technologies:
a. Selective laser melting d. WAAM
b. Electron beam selective melting e. Hybrid AM
c. Direct laser deposition f. Other techniques: metal-based FFF (Markforged, XJet, etc…).
8. Typical applications for metal 3D printing
a. Automotive c. Aerospace
b. Medical d. Other applications
Lecture Content:
- Introduction to 3D Printing: process development, types (powder bed, direct energy deposition, laminated manufacturing, etc…), application to rapid prototyping for polymers, the underlying materials science (e.g. polymer types, polymers response with temperature).
- Introduction to Metal-based 3D Printing: techniques, applications, and capabilities, etc…
- Feed-stock material for metals and polymers: filaments, resins, powder, and wire.
- Case Studies & Applications: biomedical implant, automotive, oil & gas, aerospace.
Topics' List:
1. Classification of manufacturing techniques (additive, subtractive, consolidation, conservation), highlighting process economics.
2. Definition of 3D printing technologies: CAD data, STL files, slicing, etc…
3. Overview of 3D printing classes, typical materials, feedstock material (filaments, powders, wires, etc…)
4. Description of the most common plastics 3D printing technologies:
a. Fused deposition modelling d. Material/Binder jetting 3D printing
b. Stereolithography e. Other techniques: laminated object manufacturing, solid ground curing, etc…
c. Selective laser sintering
5. 3D printing specifics: support structure, overhanging features, and post processing.
6. Typical applications for plastics 3D printing
a. Automotive c. Archaeology/conservation
b. Medical d. Other applications: casting, electronic housing, prototyping, etc…
7. Description of the most common metal 3D printing technologies:
a. Selective laser melting d. WAAM
b. Electron beam selective melting e. Hybrid AM
c. Direct laser deposition f. Other techniques: metal-based FFF (Markforged, XJet, etc…).
8. Typical applications for metal 3D printing
a. Automotive c. Aerospace
b. Medical d. Other applications
12:30 PM - 02:30 PM The 10 rules of metal additive manufacturing.
The aim of this course is to establish 10 basic rules for metal 3D printing, which address a number of critical aspects for metal 3D printing, which are: the processability of a material, the impact of platform, post-processing, approaches for process optimisation, inspection techniques, and the feedstock. The course also discusses the potential defects that occur due to metal 3D printing, suggesting approaches for mitigating them through process optimisation and post-processing
The aim of this course is to establish 10 basic rules for metal 3D printing, which address a number of critical aspects for metal 3D printing, which are: the processability of a material, the impact of platform, post-processing, approaches for process optimisation, inspection techniques, and the feedstock. The course also discusses the potential defects that occur due to metal 3D printing, suggesting approaches for mitigating them through process optimisation and post-processing
Learning Outcomes:
By the end of this course, the attendee will be able to:
1. Identify whether a material is processable by AM or not. 4.Assess the impact of AM on performance (mechanical properties). 2. Highlight the metallurgical issues with metal AM. 5. Recognise the defects associated with AM, and how to mitigate them.
3. Understand the approaches for process optimisation for AM. 6. Highlight the benefits of AM for non-conventional applications.
Instructor's Bio:
Prof. Moataz Atallah
Lecturer at the School of Metallurgy and Materials at the University of Birmingham.
Certified :
He got his BSc (highest honours) and MSc degrees from the American University in Cairo (AUC) Egypt, in mechanical engineering, and materials/manufacturing engineering respectively.
He received his PhD in metallurgy and materials science from the University of Birmingham.
His research over the past 17 years focuses on developing a metallurgical understanding of the material-process interaction in advanced manufacturing processes (additive manufacturing, powder processing, friction joining, and superplastic forming) of metallic materials, focusing on the process impact on the microstructure and structural integrity development.
He co-authored over 100 journal and conference papers, 2 book chapters, and is a co-inventor on 8 patent applications.
By the end of this course, the attendee will be able to:
1. Identify whether a material is processable by AM or not. 4.Assess the impact of AM on performance (mechanical properties). 2. Highlight the metallurgical issues with metal AM. 5. Recognise the defects associated with AM, and how to mitigate them.
3. Understand the approaches for process optimisation for AM. 6. Highlight the benefits of AM for non-conventional applications.
Instructor's Bio:
Prof. Moataz Atallah
Lecturer at the School of Metallurgy and Materials at the University of Birmingham.
Certified :
He got his BSc (highest honours) and MSc degrees from the American University in Cairo (AUC) Egypt, in mechanical engineering, and materials/manufacturing engineering respectively.
He received his PhD in metallurgy and materials science from the University of Birmingham.
His research over the past 17 years focuses on developing a metallurgical understanding of the material-process interaction in advanced manufacturing processes (additive manufacturing, powder processing, friction joining, and superplastic forming) of metallic materials, focusing on the process impact on the microstructure and structural integrity development.
He co-authored over 100 journal and conference papers, 2 book chapters, and is a co-inventor on 8 patent applications.
Prerequisite knowledge:
General engineering background, knowledge of material classes, key properties, and CAD modelling.
General engineering background, knowledge of material classes, key properties, and CAD modelling.
Selected applicants who will receive a confirmation email will be allowed to attend.