3D Printing Technologies and Processes
Description
Comprehensive study of all major additive manufacturing technologies, their principles, capabilities, limitations, and industrial applications.
Learning Objectives
Students will understand the fundamental principles of various 3D printing technologies including FDM, SLA, SLS, DLP, and metal printing processes, compare their capabilities and limitations, select appropriate technologies for specific applications, understand the physics and chemistry behind each process, and operate equipment safely while maintaining quality standards.
Topics (15)
Powder bed fusion principles, laser sintering mechanics, powder characteristics and recycling, inert atmosphere requirements, thermal management, and applications in functional prototyping and production.
Concrete 3D printing, gantry systems, robotic printing arms, large format FDM systems, construction automation, regulatory considerations, and sustainability aspects of construction 3D printing.
Dimensional metrology, coordinate measuring machines (CMM), optical scanning, surface roughness measurement, mechanical testing protocols, statistical quality control, and certification processes.
Material safety data sheets (MSDS), volatile organic compounds (VOC) emissions, nanoparticle exposure, fire safety, chemical handling, recycling protocols, and environmental lifecycle assessment.
History and evolution of additive manufacturing, comparison with subtractive manufacturing, ASTM classification of AM processes, industry applications, and future trends in 3D printing technology.
FDM process mechanics, extruder systems, heated bed technology, layer adhesion principles, print parameters optimization, support structure strategies, and quality control methods.
Photopolymerization chemistry, laser vs projector systems, resin properties and handling, support structures for overhangs, post-curing processes, and precision applications in dentistry and jewelry.
MJF thermal inkjet technology, fusing and detailing agents, voxel-level control, binder jetting mechanisms, infiltration processes, and applications in sand casting and metal parts production.
Direct Metal Laser Sintering (DMLS), Electron Beam Melting (EBM), Directed Energy Deposition (DED), metal powder characteristics, post-processing requirements, heat treatment, and quality control in metal AM.
Ceramic stereolithography, robocasting, composite filament printing, continuous fiber reinforcement, multi-material systems, and applications in electronics, aerospace, and biomedical fields.
Bioink formulation, cell viability, tissue engineering principles, organ-on-chip technologies, regulatory frameworks for medical devices, and clinical applications of 3D printed medical devices.
Design of experiments (DOE), statistical process control, parameter sensitivity analysis, quality metrics definition, automated parameter optimization, and machine learning applications in process control.
Mechanical design principles, motion control systems, stepper motors and drivers, heating systems, temperature control, firmware architecture, and hardware troubleshooting methodologies.
Continuous Liquid Interface Production (CLIP), Volumetric 3D printing, 4D printing and smart materials, molecular printing, quantum dot printing, and future manufacturing paradigms.
Technology capability matrices, application requirement analysis, cost modeling frameworks, technology readiness assessment, supplier evaluation criteria, and implementation planning methodologies.