Additive Technologies (FSI-ZAT-A)

Academic year 2022/2023
Supervisor: doc. Ing. Daniel Koutný, Ph.D.  
Supervising institute: ÚK all courses guaranted by this institute
Teaching language: English
Aims of the course unit:
Graduates will be able to design, process and produce parts using additive manufacturing. They will understand design rules, production limits and use of non-traditional design elements such as lattice structures.
Learning outcomes and competences:
Ability to design and implement parts for additive manufacturing.
Knowledge of methods of preparing production data for additive manufacturing.
Knowledge of simulation software tools for verification of manufacturability.
Ability to analyze manufacturing problems and defects.
Ability to prevent manufacturing defects by appropriate design.
Knowledge of principles of additive technologies at engineering level.
Prerequisites:
Knowledge of CAD systems (CATIA, Creo Parametric, Rhinoceros, Inventor).
Course contents:
The course introduces students to the progressive area of additive manufacturing of metal, plastic and construction products. Students will obtain practical experience with production simulation and data preparation for 3D printing. Attention is paid to understanding of design rules, technological limits and production chain of additive manufacturing. Course integrates the knowledge acquired in courses focused on materials science, CAD modeling, FEA and simulation and design of machines and mechanisms.
Teaching methods and criteria:
Lectures, exercises, laboratories, self-study.
Assesment methods and criteria linked to learning outcomes:

Course-unit credit is awarded on the following conditions: presentation of results achieved in laboratory exercises (max. 60 points).

Examination conditions:
- passing the theoretical test (max. 40 points),
- a total of up to 100 points can be earned,
- the resulting classification is determined by the ECTS scale.
Controlled participation in lessons:
Attendance at lectures is recommended; attendance at practicals and laboratory practicals is obligatory and checked by the lecturer. Compensation of missed lessons depends on the instructions of course supervisor.
Type of course unit:
    Lecture  8 × 2 hrs. optionally                  
    Laboratory exercise  8 × 2 hrs. compulsory                  
    Computer-assisted exercise  8 × 2 hrs. compulsory                  
Course curriculum:
    Lecture - Introduction to additive production - history, principle, standards.
- Process of additive production and individual technologies - metals, plastics, building materials.
- Design rules for AM parts.
- Additive production of metal parts - production chain, material, production control, physical principle, energy dissipation, support
- Additive production of metal parts - manufacturing defects, post-processing, properties of materials, influence of orientation.
- Additive production of plastic parts - technology and physical nature, materials, sizing, differences in technology, suitability of use, manufacturing defects, mechanical properties.
- Unconventional structural AM elements - periodic minimum surfaces, lattice structures, mechanical properties, dynamic properties, production limits.
- Case studies, practical examples, meaningful use of AM, impact on the economy.
    Laboratory exercise - Additive production of tensile samples by FDM and SLA technologies
- Evaluation and analysis of mechanical properties of samples
- Manufacturing of polymer part by FDM and SLA technology
- Verification of mechanical properties of the part by means of a tensile testing
- Introduction of a laboratory for additive metal production
- Post-processing of additively produced metal parts
- 3D digitization of manufactured part, evaluation of weight and relative density
- Comparison of geometric deviations of the product and reference CAD model
    Computer-assisted exercise - Data preparation for plastic 3D printing
- Basic processing of polygonal data
- Support and generation of production data
- Design rules for designing additively manufactured parts
- Shape optimization of the part
- Simulation of additive production process
- Prediction of deformations on specific manufactured parts
- Comparison of production deviations of real part and previous simulation
Literature - fundamental:
1. ELLIOTT, Amy. Additive Manufacturing for Designers - A Primer. SAE International. 2019. Dostupné z: https://app.knovel.com/hotlink/toc/id:kpAMDAP003/additive-manufacturing/additive-manufacturing
Literature - recommended:
1. GEBHARDT, A., KESSLER, J., THURN, L. 3D Printing - Understanding Additive Manufacturing (2nd Edition). Hanser Publishers. 2019. Dostupné z: https://app.knovel.com/hotlink/toc/id:kpDPUAME04/printing-understanding/printing-understanding
2. BADIRU, A. B., VALENCIA, V., VHANCE, V., LIU, D. Additive Manufacturing Handbook - Product Development for the Defense Industry.CRC Press. 2017. Dostupné z: https://app.knovel.com/hotlink/toc/id:kpAMHPDDI1/additive-manufacturing/additive-manufacturing
3. KLOSKI, Liza Wallach a Nick KLOSKI. Začínáme s 3D tiskem. Brno: Computer Press, 2017. ISBN 978-802-5148-761.
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
CŽV full-time study CZV Bases of Mechanical Engineering -- Cr,Ex 4 Compulsory 1 1 W
N-ENG-A full-time study --- no specialisation -- Cr,Ex 4 Compulsory 2 2 W
N-KSI-P full-time study --- no specialisation -- Cr,Ex 4 Compulsory 2 2 W
N-PDS-P full-time study --- no specialisation -- Cr,Ex 4 Compulsory 2 2 W