Overview

This module in Digital Manufacturing (3D Printing and Computer-Aided Manufacturing) offers a comprehensive exploration of advanced techniques and concepts at the intersection of additive manufacturing and digital production processes. This module aims to equip you with a profound understanding of the principles, tools, and applications of 3D printing and CAM in diverse industries. You will delve into topics such as additive manufacturing technologies, materials selection, process optimization, and design considerations for efficient and functional 3D-printed objects. The module also covers CAM strategies, encompassing computer numerical control (CNC) machining, toolpath generation, and process automation. By merging theoretical insights with practical hands-on experiences, you will develop the skills necessary to harness the power of 3D printing and CAM in driving innovation, improving manufacturing processes, and creating complex, customized products with precision and efficiency. Through this module, you will gain a competitive edge in industries ranging from aerospace and automotive to healthcare and consumer goods.

1. Creating good geometry - output files suitable for 3D printing
2. Intro to Cura - FDM for Creality Ender3-Pro
3. Intro to GrabCad Print - FDM for Stratasys F170
4. Intro to CHITUBOX - SLA for Anycubic Photon Mono X
5. Creating good geometry - possibilities and limitations of 3, 4 and 5 axis routing and milling
6. Intro to HSMWorks - setting up the job
7. HSMWorks - toolpath creation and strategies
8. Intro to Roland MDX-540 router - setup and cutting operations
9. Intro to HAAS Mini Mill - setup and cutting operations
10. HAAS Mini Mill - practice tasks

Assessment Strategy

-threshold -50-59%:Knowledge base covers all essential aspects of subject matter dealt with in the assignment; conceptual understanding is acceptable. Experimental work is carried out in a reliable manner, with an appreciation of data analysis shown during validation. Problems of a familiar and unfamiliar nature are solved and solutions are acceptable. Performance in transferable skills is sound. -good -60 -69%:Knowledge base covers all essential aspects of subject matter dealt with in the assignment and shows good evidence of enquiry beyond this. Conceptual understanding is good. Experimental work is carried out in a reliable and efficient manner, with a good appreciation of data analysis shown during validation. Problems of a familiar and unfamiliar nature are solved in a logical manner; solutions are generally correct and acceptable. Performance in transferable skills is sound and shows no significant deficiencies. -excellent -70% and above:Knowledge base is extensive and extends well beyond the work covered in the assignment; conceptual understanding is outstanding. Experimental work is exemplary and shows a thorough analysis and appraisal of experimental results, with appropriate and justified validation. Problems of a familiar and unfamiliar nature are solved with efficiency and accuracy; problem-solving procedures are adjusted to the nature of the problem. Performance in transferable skills is generally very good.

Learning Outcomes

• Analyse and adjust additive manufacturing and CAM parameters to optimize process outcomes, balancing factors such as speed, precision, surface finish, and material usage.

• Design and optimize 3D-printed objects, incorporating Design for Additive Manufacturing (DfAM) strategies to achieve improved functionality, reduced weight, and enhanced manufacturability.

• Develop effective computer-aided manufacturing strategies for CNC machining, including toolpath generation, speeds and feeds selection, and collision avoidance.

• Evaluate the effectiveness and appropriateness of digital CAM outputs within the context of future industrial / commercial manufacturing.