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Design for Additive Manufacturing: Towards End-Part Production Web Seminar RePlay PD331705

Newly Released!

Additive manufacturing (AM), with origins in the 1980s, has only more recently emerged as a manufacturing process of choice for functional part production, adding to the suite of choices a designer has available when designing a part for manufacturing. Like other traditional processes like casting and machining, AM has its set of constraints. An added layer of complexity comes from the fact that there are several different AM processes, and some of the design constraints are process-specific. On the other hand, AM offers a range of opportunities in design freedom and mass customization as well as in cost and lead time reduction in some cases. Today, it is essential for designers to embrace AM as a possible manufacturing method to ensure their products are competitive and also to unlock the design innovation that AM enables.

The goal of this 10-hour course is to give designers the information needed to start designing for AM at all levels - identifying and justifying use of AM technology for a particular part, selecting the right process and material for the application and ensuring it is designed with the advantages and considerations of AM in mind. The course is not intended to serve as a software-training class or as a deep dive into any specific AM process, but rather to draw connections between design and AM from a designer"s perspective.

Objectives

By participating in this course, you will be able to:

  • List the different polymer and metal AM process technologies and materials and identify which of these are being used for functional part production
  • Select the optimum AM material and process for a particular application
  • Predict how design decisions impact manufacturability for the selected AM process and apply design rules and guidelines to your design process
  • Quantify the expected properties of the AM parts you are designing
  • Discover how topology optimization, cellular structures and other disruptive design techniques can be leveraged with AM and associated software tools
  • Identify the different drivers for adopting AM for a particular part, with regard to cost, lead time, supply chain and performance risks
  • Relate to the challenges and ongoing research efforts to be able to move forward with AM implementation in the presence of rapid change in the field
  • Develop a comprehensive strategy to bring AM for functional part production into your organization that addresses both the benefits and impacts

Materials Provided

  • 90 days of online single-user access (from date of purchase) to the five session, approximately 10 hour, recorded presentation
  • Course workbook (downloadable, .pdf's)
  • Online learning assessment
  • Instructor follow up to your content questions 
  • 1.0 CEUs* (upon completion of all course modules and satisfactory assessment score)

*SAE International is authorized by IACET to offer CEUs for this course.

Is this Web Seminar RePlay for You?

This training is relevant to and needed by designers that work in aerospace and automotive companies and are chartered with either designing next generation solutions, or even with designing for cost, replacement parts or tooling used in the manufacturing process. Designers that can use existing design tools but need to learn enough about AM so they can use these tools to design parts suitable for these manufacturing processes will especially benefit from this course.

For More Details

Email CustomerService@sae.org, or call 1-877-606-7323 (U.S. and Canada) or 724-776-4970 (outside US and Canada).

Session 1: Additive Manufacturing Process
  • Introduction to AM
  • Polymer AM
    • Fused Deposition Modeling (FDM)
    • Selective Laser Sintering (SLS)
    • Other processes and trends
    • Functional parts case studies
  • Metal AM
    • Powder Bed Fusion (PBF): laser and electron beam
    • Directed Energy Deposition (DED)
    • Other processes and trends
    • Functional parts case studies
  • Material Options and Selection
  • Key Process Concepts
    • Build sizes
    • Part orientation
    • Support management
    • Post processing
  • Considerations
    • Dimensional accuracy and tolerances
    • Surface roughness
    • Physical properties
    • Mesostructure
    • Mechanical properties
Session 2: Introduction to Design for AM
  • The Need for New Design Thinking with AM
  • Four Levels of AM Design
    • Prototypes and tooling
    • Direct part replacement
    • Part consolidation
    • Design for AM optimized
  • Introduction to Software Tools for AM
    • Solid modeling (CAD)
    • Topology optimization
    • Lattice materials design
    • Build preparation
    • Process simulation
  • Support Fundamentals
    • Purpose of supports
    • Process dependence
    • Self-supporting design concepts
    • The importance of orientation
  • Build Preparation SW Demos
    • Demo with Insight (FDM)
    • Demo with Magics (Metal)
Session 3: Topology Optimization
  • Motivation: The Case for Sustainable Design
  • Case Studies with AM
  • Introduction to Optimization Concepts
  • Material Models
  • Demo with ANSYS
    • Problem setup
    • Optimization
    • Smoothing
    • Validation
  • Manufacturability
Session 4: Lattice Materials Design
  • Biometric Underpinnings
  • Classification of Cellular Materials
    • Volume/space-filling
    • Surface
  • Functions and Performance Gains
    • Structural
    • Transport
  • Case Studies with AM
  • Modeling Approaches
  • Demo with nTopology
  • Manufacturability
Session 5: Implementing AM - A Practical Guide for Designers
  • Part Selection for AM
    • Purdue scorecard for part evaluation for AM
    • Cost considerations
  • Challenges and Open Questions
    • Environment, health and safety
    • Process, supplier, equipment selection
    • Material properties and modeling
    • Process variation: repeatability, reproducibility and tool-to-tool matching
    • Design software choices
    • Data handling & traceability
    • Standards
  • Successful AM Adoption Transition Strategies
    • Polymer to metal
    • Prototype to end-use part
    • Outsourcing to in-house
  • Resources

  • Windows 7, 8, 10 (other operating systems and mobile platforms are not supported but may work)
  • Internet Explorer 11, Mozilla Firefox 37, Google Chrome 42 (other browsers are not supported but may work)
  • Broadband-1Mbps minimum

Dhruv Bhate

Dhruv Bhate is an Associate Professor at the Arizona State University (ASU), The Polytechnic School, where he conducts research in the design and mechanics of Additive Manufacturing (AM) structures and materials, and teaches courses in AM processes, design and materials at the undergraduate and graduate level. Prior to joining ASU, Dhruv spent 2 years at PADT, Inc, a small business in Tempe, AZ, where he led the company's R&D efforts in Additive Manufacturing. Prior to joining PADT, Dhruv spent 7 years at Intel Corporation developing several laser-based manufacturing processes, taking them from early-stage research to High-Volume-Manufacturing. He also spent a year in the automotive industry, working for India’s largest car manufacturer, Tata Motors. Dhruv has a Ph.D. in Mechanical Engineering from Purdue University where he developed constitutive and failure models for the prediction of fatigue fracture in ductile metal alloys. Prior to this, he obtained his M.S. from the University of Colorado at Boulder where he studied the phenomenon of adhesion in MEMS (Micro Electro Mechanical Systems) structures. Dhruv’s passion lies in combining theory, experimental methods and simulation to answer challenging research questions in new and effective ways, seeking inspiration from multiple disciplines.

1 CEUs

Access Period:90 Days

Duration: 10 Hours
Members save up to 20% off list price.
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Special Offers: To cost effectively train multiple team members, contact Corporate Learning Solutions for discount pricing. Email corplearn@sae.org, call 724-772-8529, or complete a Corporate Learning Solutions Request Form.

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