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School of Mechanical and Materials Engineering Online Courses

Part and Process Design for Additive Manufacturing

A WSU Noncredit Online Course for Boeing Employees

About the Course

This course is designed for engineers, managers and technical staff who wish to acquire practical knowledge and experience on part design and process parameter selection for additive manufacturing. The course focuses on polymers and metals and introduces method specific guidelines for designing parts and tuning the process towards realizing the benefits of AM implementations.

The course will feature practical projects where the participants will design components that will be 3D printed and get involved in the process tuning. The first two projects will involve additive manufacturing with plastics, including part consolidation and topology optimization whereas a tentative third project will focus on metal additive manufacturing.

All lectures will be delivered Tuesdays and Thursdays from 4:30 to 5:45 PM by Prof. Arda Gozen from WSU-Pullman. Students should attend the lecture from their own office or home computer, and they are expected to participate in class discussion. Additional 15 minutes (5:45 to 6 PM) will be available for any further clarification / discussion, if needed.

All lectures will be recorded and available to students during this 9 weeklong course offering (In case you miss a class or want to go over the material again).

Course objective

The primary objective of this course is to help engineers understand key principles of part design and process parameter selection to maximize the unique benefits of various additive manufacturing methods.

Course Details

Start Date: Tuesday, April 5, 2022; End Date: Thursday, June 2, 2022

Duration: 9 weeks

Lecture Hours: Tuesdays and Thursdays, 4:30 –6 PM

Format: Synchronous distance learning + hands-on projects (recorded lectures will be available online for asynchronous viewing)

Continuing Education Credits: 4

Cost: $2200

For registration questions, contact Noncredit Online Courses at 509-335-5157 or noncredit@wsu.edu.

For course related questions, contact the instructor.

Enrollment is limited to 60 students. Please register early to secure your seat. WSU may cancel the class if the number of registrants is not sufficient by the registration deadline.

Each registrant will receive a electronic copy of the required textbook*
*A Practical Guide to Design for Additive Manufacturing. Springer Singapore, 2019. Olaf Diegel, Axel Nordin and Damien Motte

Registration

Boeing employees: This program is eligible for the Learning Together Program. Please check your eligibility to participate and then go to the following website to enroll:

Part and Process Design for Additive manufacturing

Registration Deadline: March 20, 2022

Arda Gozen.

Instructor

Arda Gozen, George and Joan Berry Associate Professor, School of Mechanical and Materials Engineering, Washington State University.

https://mme.wsu.edu/arda-gozen/

E-mail: arda.gozen@wsu.edu

Phone: (509) 335-3214

Arda Gozen is an expert in manufacturing processes and machinery, with a particular on additive manufacturing with polymers, composites, and metals. He has authored 26 research articles which were cited 850 times since 2010.

Projects

Project 1 – Process-Property Relationships for Additive Manufactured Parts:
As a part of this project, participants will design and oversee the 3D printing of  several test samples made of PEEK, PEI or Nylon using the Fused Deposition Modeling (FDM) process.  These samples will be printed multiple times using various sets of process parameters including layer orientation printing speed, infill type, printing temperature. These parts will be tested mechanically and results on elastic moduli, strength and anisotropy of the parts will be provided to participants, who will elaborate on the process-property relationships they observed in a written report. The 3D printing and testing will be conducted at WSU and the results will be shared with the participants.

Project 2 – Part Consolidation and Topology Optimization:
Participants will design, and 3D print (FDM) a load-bearing PEEK, PEI or Nylon part that can only be manufactured through assembly of multiple parts using conventional manufacturing techniques. During the design of this part, participants will use topology optimization tools to determine the design modifications that will yield max stiffness with a certain amount of material savings. These parts will be 3D printed and mechanically tested against the non-topologically optimized parts. The 3D printing and testing will be conducted at WSU and the results will be shared with the participants.

Tentative Project 3 – Part Design for Metal AM (Depending on the availability of Boeing Metal AM facilities):

Project 3 – Part Design for Metal AM:
In this project, the participants will work on the same part they worked in Project 2 but 3D print it using powder-bed metal additive manufacturing. Particular focus will be on optimizing the part design to ensure removable support structures and understanding associated design limitations. The 3D printing will be conducted at Boeing facilities.

Course Outline

  1. Introduction to Additive Manufacturing and Modern Use cases
  2. Part and Process Design for Polymer Additive Manufacturing
    1. Design for material extrusion
    2. Design for powder bed fusion
  3. General Design Guidelines for Additive Manufacturing
    1. Strategic Design Considerations for AM
    2. Part Consolidation
    3. Tooling Design
  4. Topology Optimization and Generative Design
  5. Design for Metal Additive Manufacturing
    1. Design for powder bed fusion
    2. Design for electron beam melting
    3. Design for Directed Energy Deposition
  6. Post processing of the additively manufactured parts