Session: Research Posters

Paper Number: 167269

Strategies in Educating Undergraduate Students in Theory and Practice of Additive Manufacturing 

The growing need for ever-changing customer demand pressurizes the manufacturing industry to look for a flexible and fast-changing small-volume production system.  As a result, additive manufacturing (AM) is one of the fastest-growing methods of changing a 3D design model to a 3D product without any process planning method. The process is commonly called as 3D printing technology and has found extensive applications in areas such as automotive, architecture, manufacturing, aerospace, thermal, flexible electronics, medicine, fashion, retail, and sports. A major aspect of 3D printing technology is its ability to produce parts which are not possible by traditional manufacturing techniques. The students at any level can be introduced to the technology and understand the theoretical aspects in coordination with practice in the laboratory. The paper examines the underlying 'rules' that help companies take full advantage of additive manufacturing technologies. The paper also examines the guidelines for the design of additive manufacturing with in-depth discussion of design constraints. These guidelines are discussed with the view of creating light weight parts, efficient heat exchangers and components for aerospace industries. The paper investigates different influencing variables including the variation due to density and porosity. Other modeling equations that influence the additive process are examined, which include energy balance equations for melting and vaporization. Post processing of 3D additive components is also critical to the outcome of overall process as it impacts resulting surface quality, total cycle time and cost. Exposing students to various additive manufacturing processes is crucial for their education and career readiness. It cultivates a diverse skill set, enabling them to adapt to evolving technologies in fields like engineering and design. Understanding different processes, such as Fused Deposition Modeling (FDM), Stereolithography (SLA), and Selective Laser Sintering (SLS), enhances problem-solving abilities and creativity. Exposure to diverse techniques fosters critical thinking, enabling students to choose the most suitable method for specific projects. This comprehensive knowledge prepares them for the demands of a dynamic job market, encouraging innovation and a deeper understanding of the rapidly advancing field of additive manufacturing.AM employs a variety of materials, energy sources, and techniques to create objects layer by layer from digital models. Materials range from thermoplastics and metals to ceramics and biomaterials. Thermoplastics, like ABS and PLA, are prevalent in desktop 3D printing, while metals such as titanium and aluminum are used in industrial applications One example of a typical research  project is the creation of heat exchanger. Conventional manufacturing techniques have a limitation in producing parts of a complex design of geometries. Additive manufacturing techniques provide flexibility of design and allow fabricating novel devices such as miniaturized heat exchangers.   Minjiaturized  Heat exchangers are a valuable part of most heating and cooling appliances and systems at home and in the workplace. One of the challenges in heat exchanger fabrication is the creation of micro channels.  The removal of high heat flux from a microelectronic circuitry is one of the most important applications of microchannels. When the channel dimensions are decreased, heat transfer coefficients become large which will improve the heat transfer. The presentation highlights the complex the design of heat exchanger fabrication by additive manufacturing.

Keywords: Additive process, Design guidelines for AM, Equations for AM

Presenting Author: Devdas Shetty UDC

Presenting Author Biography: Dr. Devdas Shetty is the Dean and Professor at the University of the District of Columbia, Washington DC.

Authors:

Devdas Shetty UDC
Claudio Campana University of Hartford
Pablo Sanchez Guerrero University of the District of Columbia