Faysal AzizAdditive Manufacturing Foundations
Design, materials, processes and practical 3D printing
Why this course
An introductory course exploring the additive-manufacturing workflow from a digital design to a printed part. Participants compare representative polymer and metal processes, consider material and design constraints, and practise a small design-to-print workflow in a prepared learning environment.
Hands-on work uses one available printer and material; other processes and industrial applications are examined through demonstrations and case studies. Two days provide foundations, not qualification to manufacture certified aerospace or medical components.
Learning outcomes
- Explain the principal additive-manufacturing process families and compare representative applications.
- Identify design, orientation, support and material considerations for a simple part.
- Prepare and review a small model for an available 3D-printing process.
- Describe common post-processing and quality checks, including the limits of a learning prototype.
Prerequisites
- Basic familiarity with manufacturing concepts is helpful.
- Prior CAD experience is useful but not required; a prepared example is provided.
- Use the arranged CAD/slicing tools and supervised printer environment.
2 modules
01Day 1 — Processes, Design and Materials1 topics
Additive-Manufacturing Fundamentals
- Layer-by-layer workflow, digital models, slicing and the development of 3D printing.
- Material extrusion, vat photopolymerisation, powder-bed fusion, binder jetting and material jetting; representative FDM, SLA, SLS, laser-metal and vendor-specific processes.
- Compare mechanisms, machine components, materials, applications and practical limitations.
Design for Additive Manufacturing
- Introduction to DfAM Principles
- Considerations for Additive Manufacturing
- Design complexity and customization
- Part orientation and support structures
- Minimizing material usage and print time
- Software Tools for Additive Manufacturing Design
- Case Studies: Real-world DfAM Examples
Materials and Process Selection
- Overview of Materials Used in Additive Manufacturing
- Plastics and Polymers
- Metals and Alloys
- Ceramics and Composites
- Material Selection Criteria for Additive Manufacturing
- Properties and Applications of Various Materials
02Day 2 — Quality, Applications and a Design-to-Print Exercise1 topics
Process Comparison
- Detailed Exploration of Key Additive Manufacturing Technologies
- Process Mechanisms
- Machine Components and Operation
- Applications and Case Studies for Each Process
- Comparative Analysis of Additive Manufacturing Technologies
Post-Processing and Quality
- Overview of Post-Processing Requirements
- Techniques and Tools for Post-Processing
- Cleaning and Support Removal
- Surface Finishing Methods
- Heat Treatments and Other Post-Processing Methods
- Quality Control and Testing
- Quality Assurance in Additive Manufacturing
- Testing Methods for Additive Manufactured Parts
- Standards and Certification in Additive Manufacturing
Post-processing and inspection depend on the material and process. Discuss standards and qualification as context; this course does not certify parts or operators.
Applications and Case Studies
- Industry-specific Applications
- Aerospace and Defense
- Medical and Dental
- Automotive
- Consumer Products
- Emerging Trends and Future of Additive Manufacturing
Treat sector examples as illustrative and assess suitability against cost, repeatability, material properties and qualification requirements.
Practical Session
- Hands-on Experience with 3D Printing
- Designing a Simple Object for 3D Printing
- From Design to Print: A Step-by-Step Guide
- Conclusion and Future Outlook
- Recap of Key Learning Points
- Discussion on the Future of Additive Manufacturing
- Q&A Session
Design or adapt a simple part, inspect orientation and supports, prepare a print and review the result. Printer safety and material handling follow the prepared lab's instructions.
A programme built around your team.
Share your training goals and requirements.