Additive Manufacturing Technologies for Practising Engineers – Cohort 2

Last Day for Registration : June 20, 2024

SKU: IIT Madras | Start Date: July 1, 2024 Categories: ,

Course Description

Course – Teaser Video

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About The Course:

Additive manufacturing (AM) is emerging as an attractive process to produce various engineering and biomedical components. There is a huge potential for use of AM in various Engineering and Biomedical applications. It has already emerged as a viable, cost effective and net shape manufacturing process for low volume production of complex body implants with specific custom-made designs.
This course is aimed to provide a comprehensive overview of pre and post-processing methodologies, design strategy for additive manufacturing and operational principles of additive manufacturing processes. Practicing engineers can learn about the fundamental principles that govern various additive manufacturing methodologies and how the developed knowledge is applied in-service to improve the commercial applicability of available additive manufacturing technologies. Upon completion of this course, learners can jump-start their career in the area of additive manufacturing.

Mode: This course comprises of 72 hours of recorded videos and 24 hours of ONLINE interactive sessions with the faculty. 

The course is structured in the following manner:

  • Participants need to watch around 6 hours of video content (not more than 3 hours in a particular module) every week. 
  • A live interaction session would be scheduled every Saturday with the corresponding faculty to discuss the module content and clarify queries. The duration of this session would be 1 hour.

Modules Covered:

MODULE-1: Processes
MODULE-2: Design
MODULE-3: Materials
MODULE-4: Post Processing
MODULE-5: Testing and Standardisation
MODULE-6: Application and Case Study
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Click on the tab “Module Description” and choose the appropriate module from the dropdown menu to view more information about each modules.

Certification of completion would be awarded to the participants on fulfilling the following criteria

1. Attend all the Live sessions with active participation.

2. Submit assignments and final evaluation of all modules.

3. Submit feedback forms for all modules

Session dates: Starting July 1 , 2024

Time: Recorded lectures on weekdays and Online Live session on Saturdays.

Last date of Registration: June 20, 2024

Instructors

Prof. Murugaiyan Amirthalingam , Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. Saravana Kumar , Department of Engineering Design , IIT Madras

Prof. G. D. Janaki Ram, Department of Materials Science and Metallurgical Engineering , IIT Hyderabad

Prof. Ratna Kumar Annabattula, Department of Mechanical Engineering , IIT Madras

Prof. Ravi Sankar Kottada , Department of Metallurgical and Materials Engineering, IIT Madras

Prof. Lakshman Neelakantan, Department of Metallurgical and Materials Engineering, IIT Madras

Module Description

MODULE – 1 : Processes

Module Duration:

12 hours of recorded videos and 4 live online interactive sessions.

Faculty Profile:

Prof. Murugaiyan Amirthalingam

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. D. Janaki Ram

Department of Materials Science and Metallurgical Engineering, IIT Hyderabad

Topics covered:

This module is designed to provide a basis about the background, nomenclature, advantages of additive manufacturing as compared to conventional subtractive and formative processes. This module will cover in detail about the operating principles of the 7 types of additive manufacturing processes, underlying principles on the feedstock consolidation strategies, defects formation and control and engineering limitations of these processes.

Learning Outcomes:

  1. To understand the fundamentals of AM processes.
  2. To critically evaluate the physical principles of an AM process.
  3. To obtain an ability to choose correct AM process for a given material, design and service condition

Applications of the Module:

Upon completion of this module, the learner should be able to choose a correct AM process for a given material and in-service processing condition.

MODULE – 2 : Design

Module Duration :

12 hours of recorded video and 4 live online interactive sessions.

Faculty:

Prof. G. Saravana Kumar

Department of Engineering Design, IIT Madras

Module Description:

Design for additive manufacturing (DfAM) bring challenge to traditional computer aided design (CAD) and analysis since most of them can only deal with homogeneous materials as of now, and also in terms of understanding the constraints posed by the AM process
while employing generative design to obtain functional designs with complex geometry.
This module shall provide the participants outline on existing solid modeling framework, preprocessing CAD data for additive manufacturing, generative design concepts and analysis of distortions, stress evaluation in AM components.

Learning Outcomes:

  • Part modeling in CAD, Solid modeling, B-rep data structure.
  • Data file formats, STL, AMF, STL pathologies and its mitigation.
  • Support structure generation, Slicing and Tool path generation.
  • Process simulation of LPBF process to predict distortion and stress evaluation.
  • Generative design with AM constraints

Applications of the Module:

  • Explore design freedom offered by AM in all areas of industrial application.
  • Explore light weighting by design and additive manufacturing.
  • Explore AM for prototype molds and parts for vendor qualification.
  • Explore one off design / very low volume production of metallic parts with enhanced properties.
  • Explore tool and die design with conformal cooling channels.
  • Explore part consolidation to reduce assembly and improve precision.
  • Explore customised patient specific biomedical implants.

MODULE 3 : Materials

Module Duration:

12 hours of recorded video and 4 live online interactive sessions.

Faculty Profile:

Prof. Ravi Sankar Kottada

Department of Metallurgical and Materials Engineering, IIT Madras

Module Description:

This module is designed to provide a basic understanding of fundamentals of physical metallurgy, including role of alloying elements on solidification and phase transformation behavioural, classification of ferrous and non-ferrous alloys, alloy development strategy for additive manufacturing and introduction to polymer and ceramic feedstock materials used for additive manufacturing.

Learning Outcomes:

To provide a comprehensive understanding of the micro structural evolution of an alloy component during additive manufacturing

To provide a basis of feedstock thermal-mechanical behaviour during additive manufacturing of polymer and ceramic materials

Applications of the Module :

Any engineering or biomedical application where additive manufacturing is used to produce end-use components.

MODULE 4: Post Processing

Module Duration:

12 hours of recorded videos and 4 live online interactive sessions.

Faculty Profile:

Prof. Ratna Kumar Annabattula,

Department of Mechanical Engineering, IIT Madras

Prof. Lakshman Neelakantan

Department of Metallurgical and Materials Engineering, IIT Madras

Topics covered:

Additively manufactured materials and components are generally rough, which requires post processing using various conventional and novel processes. This module will provide an outline on general post processing strategies and specifically on the electrochemical processing of metals and alloy systems, to achieve smooth, bright and stress free surfaces.

Learning Outcomes

  •  Differentiate various surface processing techniques.
  • Identify the difference between conventional electrochemical and plasma electrolytic -processing.
  • Identify the components and build electrochemical cells for electrochemical processing.
  • Differentiate various mechanisms involved in electropolishing.
  • Apply electrochemical principles to identify optimal electrochemical processing conditions.
  • Evaluate the surface finish and corrosion properties of the modified surface.

Applications of the Module

The participants will be able to use the concept of surface finishing for 

  • Additive manufactured components, 
  • Tool for surface engineering, 
  • Strategy for corrosion prevention
  • Apply in biomedical 

MODULE 5: Testing and standardization 

Module Duration:

12 hours of recorded videos and 4 live online interactive sessions.

Faculty:

Prof. Murugaiyan Amirthalingam,

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. Ravi Sankar Kottada

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. D. Janaki Ram

Department of Materials Science and Metallurgical Engineering, IIT Hyderabad

Module Description:

This module is designed to provide a comprehensive overview of the various mechanical testing methods used to qualify an additive manufactured component for engineering and biomedical applications. The qualification strategies adapted for Aerospace, Defence, Automotive and Biomedical components made by additive manufacturing are also elicited. 

Learning Outcomes: 

To obtain a comprehensive understanding of various testing and qualification strategies used for additive manufactured components for Aerospace, Defense, Automotive and Biomedical applications

Applications of the Module: 

Aerospace, Defense, Automotive and Biomedical industries who are aspiring to commercialise additively manufactured components

MODULE 6: Application and Case Studies

Module Duration : 

12 hours of recorded videos and 4 live online interactive sessions.

Faculty Profile: 

Prof. Murugaiyan Amirthalingam,

Department of Metallurgical and Materials Engineering, IIT Madras

Prof. G. Saravana Kumar

Department of Engineering Design, IIT Madras

Prof. G. D. Janaki Ram

Department of Materials Science and Metallurgical Engineering, IIT Hyderabad

Topics covered:

The module shall showcase industrially relevant, contemporary applications of AM in automotive, Aerospace, Defense and Medical industry.

Learning Outcomes:

Success stories where additive manufacturing led to disruptive technological breakthroughs in automotive, aerospace and biomedical applications. 

Identify candidate applications which can benefit from AM intervention.

Benchmark application case studies in AM, to aspire exploring AM to its fullest potential.

Applications of the Module :

Application development for the use of additive manufacturing in Automotive, Aerospace and Biomedical  applications.

Learning Objectives of the course

  • Understand the fundamentals of AM processes, materials and design for AM and post processing methodologies.
  • Learn the generic process chain of AM Technologies by hands-on training
  • Obtain an ability to apply AM technologies disruptively in various engineering industries
  • Analyse and appreciate the impact of AM technologies in product design and development. 
  • Comprehend the testing, qualification and standardisation methods and procedures for AM materials and components.

Eligibility & Audience

Eligibility :

Minimum of a Bachelor’s degree in Engineering or Applied Sciences or Basic Sciences with at least 3 years of working experience.

Intended audience:

Practicing engineers, scientists, medical professionals, faculty members and research students

Fees

Course fees:  Rs. 1,18,000 (Rs. 1,00,000 + 18% GST)

Course fees can also be paid in instalments.

The following 2 options are available:

  • 2 installments of Rs.59,983 each
  • 6 installments of Rs.20,158  each

NOTE: The first installment is to be paid on registration and the next installments over the course period.

Bulk discounts are available for corporate nominations under single billing.

Certification

Certification of completion would be awarded to the participants on fulfilling the following criteria

Certificate criteria for this course would be as follows:

Total % will be calculated from all 3 categories (Assignments, Quizzes and Attendance of Live sessions)

Type of certificate that will be issued

75% -100% Successfully completed
50% -74% Completed
25% – 49% Participated
<25% No Certificate

Course Certificate Template

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