Design and Introduction to Applications in 3D Printing

Examine the principal additive manufacturing processes, advantages and disadvantages, and the six steps and seven rules of 3D printing, with practical examples and quizzes.

Explore the seven ASTM additive manufacturing processes, classified by dimensional build methods and feedstock—powder, liquid, and sheet materials—and compare rapid prototyping with rapid manufacturing in the context of 3D printing.

Evaluate the advantages and disadvantages of additive manufacturing, including automation, customization, rapid prototyping, complex geometries, faster design iterations, time to market, supply chain impacts, and material availability.

Learn the six steps for winning in 3D printing, from design freedom and lightweight structures to optimization of functionality, anisotropic materials, lifecycle sustainability, and hyper personalization in low-volume production.

Explore the seven rules for additive manufacturing, including design decisions, process comparisons, orientation for isotropic or anisotropic parts, and minimizing material and supports to control costs.

Explore the range of 3d printing technologies—from extrusion and vat polymerization to binder jetting and powder bed fusion—and learn design for additive manufacturing, model preparation, and post-processing.

Explore material extrusion (fused filament fabrication, FDM) and its nozzle-based, layer-by-layer process, including filaments, supports (breakaway or soluble), orientation, infill options, walls and holes, plus post-processing and education versus industry.

Explore the photopolymerization process in SLA/DLP 3D printing, detailing liquid resin in a vat, UV curing, post-processing, and design considerations for supports, walls, and overhangs.

Explore material jetting, an additive process that deposits droplets cured by UV or thermal changes to produce polymers, wax, and parts. Learn about Stratasys poly jet systems and jewelry applications.

Explain binder jetting: inkjet binder binds powder to form green parts, later consolidated by sintering or infiltration, with color printing and fast builds but weaker green parts and material limits.

Powder bed fusion uses thermal energy to selectively fuse powder bed regions, printing polymers like nylon and metals or ceramics layer by layer for complex parts.

Explore direct energy deposition, an additive manufacturing process using focused energy, such as laser or electron beam, to fuse powders or wires into near-net shapes and enable repairs.

Explore sheet lamination, a low-cost additive process using paper sheets and a polyethylene-coated layer, bonded by heat, with a CO2 laser cutting cross-sections to form large nestable parts.

Explore the hybrid manufacturing process that blends 3d printing with subtractive and forming methods, enabling multitask systems and robotic arms to produce final parts with metal and resins.

Discover the cold spray process for forming metal matrix composites by spraying powders without melting, and examine its aerospace, defense, tooling, and medical device applications along with market players.

Master general rules for design for additive manufacturing, including defining the design space and selecting materials. Apply constraints like 45-degree overhang limits and optimal print orientation to improve part performance.

Prepare a 3-D model for printing by planning pre-processing and post-processing, determine build orientation, decide on supports and build parameters, and assess material choices to optimize quality and production.

Explore post-processing of 3-D parts, from powder removal and heat treatment to stress relief, porosity closure, and surface finishing for accurate geometry and material properties.

Explore heat treatments for metal 3d printed parts, including stress relief, quenching, annealing, and hot isostatic pressing (hipping), to reduce residual stresses, improve microstructure, and enhance fatigue life.

Explore case studies and applications of additive manufacturing in 3-D printing design, gain industry perspectives, and develop a business case through topic-based lessons and practice.

Examine common perceptions of additive manufacturing: recognize limitations like feature size and tolerances, weigh complex geometries against material and process boundaries, and assess production viability.

Develop a business case for 3D printing by optimizing production-focused design, selecting suitable laser sintering and polymer/metal options, and addressing materials, costs, and supply-chain challenges.

Explore topological optimization for general shapes and learn about new IAM techniques and the next journey in AMM technology, with real-life examples.

Discover topology optimization and generative design as algorithm-driven CAD tools that create organic shapes by removing or adding material to meet constraints. Validate with final design testing and manufacturing constraints.

Explore how to design 3D printed parts with supports and new additive manufacturing techniques, mastering process workflow, tolerances, and post-processing for on-demand composite fiber solutions.

Identify the progression from level zero prototypes to level four masters in additive manufacturing, and apply design for additive manufacturing, machine types, and process economics.