The low-volume production of parts with highly complex geometries has long been regarded as an economically unfeasible task with traditional manufacturing processes. Such belief is now changing because engineers have new options:
• Additive Manufacturing (AM) processes, often referred to as the term of 3D Printing, allow building the parts additively, layer by layer, according to a computerised trajectory of the tool, with few geometrical constraints, if compared to conventional processes;
• Virtual Manufacturing is increasingly used for the representation of manufactured products and simulation of manufacturing processes, this accelerates the process planning phase and the definition of the computerized trajectories of the tool.
The DIGITAL MANUFACTURING course integrates two educational modules (ADDITIVE MANUFACTURING and VIRTUAL MANUFACTURING) covering these two important disciplines of modern, digital manufacturing.

Refer to the individual courses for a detailed description.

This course integrates two educational modules covering these two important disciplines of modern, digital manufacturing.

Additive Manufacturing

This module will provide an introduction to the AM processes and their applications, discussing their technical and business-oriented implications for designers, engineers, “makers” and other possible users of this advanced manufacturing technology.

• Introduction. Layer-by-layer principle. Benefits and limitation of AM. Historical development of AM technology. Generalized AM process chain. Materials and industrial applications: rapid prototyping, rapid tooling, direct digital manufacturing. Process selection, market availability and trends, business opportunities.
• AM technology: Polymers. Description and modeling of the main AM processes for polymers. Machines, software issues, post-processing, design for.
• AM technology: Metals. Description and modeling of the main AM processes for metals. Machines, software issues, post-processing, design for.
• AM product verification. The need for precision metrology.Dimensional and geometrical metrology for AM: limits of tactile and optical measuring systems; volume based measuring systems: 3D X-ray computed tomography. Surface topography measurement (tactile, optical, other, analysis methods).
• AM process monitoring. The need for precision processing. In-line monitoring for AM: process variables measurement, monitoring approaches, sensor and data fusion.

Virtual Manufacturing

The module aims at preparing students to the fundamentals of virtual manufacturing as a component of digital manufacturing, with particular attention to the additive manufacturing applications.

-  Introduction to virtual manufacturing: Virtual manufacturing definition and applications.

- Geometric Modeling: Approaches to Geometric Modeling. Curve Theory: parametric line, cubic spline curve, Bezier spline curve, Bspline and NURBS. Surface theory: bilinear surface, ruled surface, general curved surface. Solid Modeling: R-sets and regularized set operators, parametric representation, sweep representation, Boundary representation, CSG representation, decomposition schemes (mesh, STL, voxel-based). Introduction to reverse modelling.

- CAD/CAM: The operation and programming of CNC machine. Approaches to computer-aided design and manufacturing.

- CAD/CAM Project Work: Within the semester, each student has to carry out a mandatory team project work. Each team will be composed of up to 3 students. The team project work has to be reported and discussed by the end of the semester.

Organization

The course is based on a mix of lectures, discussion of case studies, testimonials from industry, in-class exercises, laboratory activities, training at the computer. Laboratory activities will be held at AddMe.Lab of the Mechanical Engineering Department and allow students to develop hands-on knowledge on specific AM problems and their virtual representation.

Refer to the individual courses for a detailed description.

Additive Manufacturing

An optional team project will be possible. Grading will be based on an oral examination, which may include the discussion of the project.

Virtual Manufacturing

A mandatory team project will be assigned. Grading will be based on the mandatory team project work and on an oral examination