ISE 589: Fundamentals of Additive Manufacturing

Offered: Every Fall 

Class Enrollment: 30

Pre-requisite: ISE 316 or Graduate Standing in College of Engineering

This course is intended to introduce students to the theory and applications of Additive Manufacturing processes, or more commonly referred in mainstream media as “3D Printing”. Class sessions will be divided into both theory and laboratory based sessions. Within the theoretical portion, students are expected to gain an in-depth understanding of additive manufacturing processes and basics of the additive manufacturing workflow – both software and hardware related. To complement theoretical knowledge, students will be trained on state-of-the-art commercial software using 3D Systems Geomagics and Materialise MAGICS using a variety of case-study type datasets and hands-on experience with AM machines. 

Students will be required to participate in groups on ONE of three project themes - 1) A Toy Redesign Challenge; OR 2) Personalized Ornaments, Gifts and Jewelry Challenge; OR 3) Personalized Wearables – Healthcare or Fashion related. To accommodate the different majors and interests in class, certain assignments and discussion topics will be geared towards students’ personal interests in an area of interest within 3D Printing. The only requirement will be that learning obtained through such methods must be shared with everyone in class. 

Textbook: “Additive Manufacturing Technologies”, Brent Stucker, Ian Gibson, Springer ISBN 978-1-4939-2112-6. This book is available to download for free through NCSU Libraries.

Lecture Outline: 

Part 1: Principles and Applications of Additive Manufacturing Technologies

  • Additive Manufacturing Workflow and Process Chain

  • Powder Based Systems

  • Extrusion Based Systems

  • Ink-Jet Based Systems

  • Photopolymerization Based Systems 

Part 2: Reverse Engineering from Physical Object to Digital Model and back to Redesigned Physical Object

  • 3D Scanning and Point Clouds via FARO Laser Scanner

  • Point Cloud Editing via 3D Systems Geomagics Software

  • STL Model Analysis Using Materialise MAGICS

  • Printing Models with Additive Manufacturing Processes

  • Comparing and Qualifying Parts using Geomagics QUALIFY

Part 3: Under the Hood and Systemic Issues in Additive Manufacturing

  • Design for Additive Manufacturing

  • Slicing, Support Generation and File Formats in Additive Manufacturing

  • Process Selection and Cost Estimation of AM Processes

  • Process Monitoring and Control of AM processes.

  • Challenges in Additive Manufacturing – Aerospace, Automotive, Medical and Consumer Products

  • Future Applications and How to Make Money from 3D Printing

Download the Syllabus: Fall 2016