Additive Manufacturing: From 3D Printing to the Factory Floor
Date: July 25-29, 2016 | Tuition: $4,700 | Continuing Education Units (CEUs): 3.3
*This course has limited enrollment. Apply early to guarantee your spot.
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Additive manufacturing (AM) processes were first demonstrated more than 25 years ago; however, only recently has broad industrial and consumer interest ignited, with potential implications ranging from ubiquitous personal fabrication to disruption of traditional supply chains. The goal of this course is to present a comprehensive overview of AM, spanning from fundamentals to applications and technology trends, and with strong focus on high-performance materials. Participants will learn the fundamentals of AM of polymers, metals, composites, and biomaterials, and will realize how process capabilities (rate, cost, quality) are determined by the material characteristics, process parameters, and machine designs. Application areas including aerospace components, electronics, medical devices, and consumer products will be discussed via detailed examples and case studies. Particular emphasis will be placed on metal- and powder-based AM technologies, and related design principles and process standards to achieve high-performance materials and novel properties via AM. Lab sessions will provide hands-on experience with a variety of state-of-the-art AM equipment. Participants will design, fabricate, and measure test parts, and will perform experiments to explore process limits. The course will conclude with discussion of how AM will influence existing business models in design and manufacturing, will pose major opportunities and needs for advancement.
Fundamentals: Core concepts, understandings, and tools (40%)
Latest Developments: Recent advances and future trends (30%)
Industry Applications: Linking theory and real-world (30%)
Lecture: Delivery of material in a lecture format (50%)
Discussion or Groupwork: Participatory learning (25%)
Labs: Demonstrations, experiments, simulations (25%)
Introductory: Appropriate for a general audience (35%)
Specialized: Assumes experience in practice area or field (50%)
Advanced: In-depth explorations at the graduate level (15%)
Participants of this course will:
- Learn the fundamentals of additive manufacturing (AM) of polymers, metals, and ceramics, along with those for emerging materials (e.g., nanocomposites, biomaterials) and complex architectures.
- Understand the operating principles, capabilities, and limitations of state-of-the-art AM methods, including laser melting, fused deposition modeling, stereolithography, and jetting.
- Understand the principles of "Design for Additive Manufacturing" and compare and contrast additive processes with conventional manufacturing methods such as machining and molding in terms of rate, quality, cost, and flexibility.
- Gain hands-on experience with a variety of AM machines; use these machines to fabricate example parts, post-process the parts, and study the results.
- Become familiar with the complete workflow of AM, including computational design tools, file formats, toolpath generation, scanning, and microstructure characterization.
- Study applications of AM across industries, including aerospace/automotive, medical devices, energy, electronics, and consumer products.
- Via examples and case studies, understand how to quantitatively assess the suitability of AM for an application, and realize how this justification will change as AM improves.
- Place AM in the context of the evolving manufacturing infrastructure, including advances in robotics, software, logistics, and digitization of data.
Who Should Attend
This course will be useful to design engineers, manufacturing engineers, product designers, research engineers, research scientists, managers, VPs of product development and manufacturing, and technology and innovation strategists, from industries such as aerospace, automotive, medical devices, electronics, consumer products, energy, and robotics. The course material is accessible for those new to AM, yet highly comprehensive and valuable for those who already have significant experience with AM.
Day 1: (9.30 am - 5.30 pm)
- Introduction to additive manufacturing (AM)
- AM technology and market landscape
- Emerging trends and business models
Lunch: Participant introductions; discussion of course schedule
- Hands-on lab: Anatomy of AM machines
- Design case study part I
- AM parts to conventional processes
Day 2: (8.30 am - 5.30 pm)
- Extrusion AM processes (polymers and composites)
- Photo-polymerization AM processes (polymers and ceramics)
Lunch: Jetting and lamination AM processes
- Hands-on lab: Fused deposition modeling (FDM) and stereolithography (SLA)
- Mechanics of polymer AM parts
- Design case study part II
Day 3: (8.30 am - 5.30 pm)
- AM of metals: Selective laser melting, e-beam melting, direct powder deposition
Lunch: Qualification of AM parts, with focus on metals
- Hands-on lab: selective laser melting
- Hands-on lab: 3D scanning
- Geometry and property optimization
Day 4: (8.30 am - 5.30 pm)
- Cost and business case analysis for AM
- Industry focus: Aerospace components, medical implants, tooling, and consumer goods (includes guest speakers)
Lunch: Continued discussion of industry applications and needs
- Integration of AM and electronics
- AM of biomaterials and tissues
- Design case study part III
Day 5: (8.30 am -1.30 pm)
- Group case-study presentations
- Future trends and implications of additive manufacturing: logistics, mass-customization, and emerging business models.
Lunch: Continued discussion and wrap-up
Course schedule and registration times
Class runs 9:30 am-5:30 pm on Monday, and 8:30 am-5:30 pm the rest of the week, except Friday, when it ends at 1:30 pm.
Laptops or tablets are encouraged for this course.
Ceramic Engineer, Defense Industry
"We are creating an additive manufacturing plan for the future and the material learned in this course will be invaluable for this exercise."
Independent Management Consultant
"The professor gave an excellent review of all of these complex subject matters in a short time. He was able to tailor it for the novice as well as for experts in various subject areas."
Head of Innovation, Advanced Materials Industry
"Rich content and great delivery."
President, Technical Consulting Firm
"I got an excellent understanding of the scope and state-of-the-art for AM covering the full range of materials and mega to nano applications."
Business Innovation Manager, Medical Device Industry
"I feel like an expert now."
Mechanical Engineer, Transportation Industry
"If you want to get up to speed on AM in just a week, I don't think there is a better way to do it."
Mechanical Engineer, Energy Industry
"The course covered everything in explicit detail."
About The Instructor
John Hart is associate professor of Mechanical Engineering and Mitsui Career Development Chair at MIT. Hart directs the Mechanosynthesis Group, which aims to advance the science and technology of advanced manufacturing in areas including additive manufacturing, nanostructured materials, origami-inspired engineering, and integration of computation and automation to accelerate material and process discovery. Hart teaches undergraduate and graduate courses in manufacturing processes, advanced materials, and research methods. He has PhD (2006) and SM (2002) degrees from MIT, and a BSE (2000) degree from the University of Michigan, all in Mechanical Engineering. Prior to joining MIT in 2013, Hart was Assistant Professor of Mechanical Engineering, Chemical Engineering, and Art and Design at the University of Michigan.
Hart has received numerous prestigious awards recognizing his accomplishments in research and teaching, and his impact on the development of innovative materials and manufacturing technologies. These include: the R&D100 Award (2008, 2009), the DARPA Young Faculty Award (2008), the ASME Pi Tau Sigma Gold Medal (2009), the SME Outstanding Young Manufacturing Engineer Award (2010), the AFOSR Young Investigator Program (YIP) Award (2011), the NSF CAREER Award (2012), the ONR YIP Award (2012), and the ASME Best Paper Award in Compliant Mechanisms (2013). Hart is also internationally recognized for his efforts to communicate principles of nanotechnology to the public, including his Nanobliss site.
This course takes place on the MIT campus in Cambridge, Massachusetts. We can also offer this course for groups of employees at your location. Please complete the Custom Programs request form for further details.