Additive Manufacturing Education: Session I
Program Organizers: Somayeh Pasebani, Oregon State University; Hang Yu, Virginia Polytechnic Institute and State University; Amy Elliott, Oak Ridge National Laboratory

Monday 8:00 AM
September 30, 2019
Room: B111
Location: Oregon Convention Center

Session Chair: Amy Elliott, Oak Ridge National Laboratory; Hang Yu, Virginia Polytechnic Institute and State University

8:00 AM  Invited
Additive Manufacturing Education at Georgia Tech: David Rosen1; 1Georgia Institute of Technology
    Additive manufacturing offers a collection of novel manufacturing processes that enable opportunities for customized products, complex geometries, novel design concepts, and new business models. From an educational perspective, these aspects of AM present significant challenges to convey the breadth and depth of AM technologies, capabilities, and opportunities. To address these challenges, the AM educational program at Georgia Tech is presented that consists of an advanced graduate course, two 5-week undergraduate “minimester” courses, and informal educational activities in our Invention Studio. The graduate course covers AM process models, design for AM methods and technologies, and a project focusing on either technology development or DFAM. The undergraduate courses provide an introduction to AM processes, an exploration of prototyping technologies in product development, an overview of process modeling and process selection, and hands-on experimentation. Learning objectives and examples of course content and projects are presented to illustrate examples of our educational strategy.

8:30 AM  Invited
Data Analytics for Metal Additive Manufacturing: Amir Mostafaei1; Nihal Sivakumar1; David Crockett1; Anthony Rollett1; 1Carnegie Mellon University
    Producing defect-free parts with required microstructure and mechanical strength are necessary for the continued rapid growth of metal additive manufacturing (AM). The variation in feedstock powder, processing parameters during a build fabrication and post-processing can contribute to the reduction of defects. We are developing an image-oriented database to consolidate and analyze the data gathered from powder bed metal AM processes to identify the necessary parameters to produce defect-free parts. One issue was that so many different experiments had different parameters that consolidation into a single information file was difficult. The data gathering process had to be designed to include the parameters that were general to all experiments, and a filter search bar was introduced to allow users to search for specific key terms that return specific images. Ultimately, we aim to enable efficient machine learning on a wide range of materials, processes and imaging modalities.

9:00 AM  Invited
Engineering Better Additive Manufacturing Education: Leveraging Research-based Approaches to Prepare the Future Workforce: Nicholas Meisel1; 1Pennsylvania State University
    Industry demand for a skilled additive manufacturing (AM) workforce is rising rapidly. However, despite the growing prevalence of AM systems and education at the university level, workforce demand is not being met. Further, the majority of AM education research is still in the nascent stages. This makes it difficult to ensure that teaching approaches are effectively and efficiently preparing students to understand, use, and design for modern AM technology. In response to this gap, this presentation discusses research-based approaches to AM education, with particular emphasis on teaching design for additive manufacturing concepts. Examples draw from ongoing research and practice at Penn State and include investigations into the use of problem-based learning and virtual reality to affect how students consider design for AM. Discussion will also include details regarding the design and implementation of a first-of-its kind Additive Manufacturing and Design master’s degree program offered simultaneously in-residence and online.

9:30 AM  Invited
Additive Manufacturing in Capstone Design Projects at Materials Innovation Guild @ University of Louisville: Vamsi Balla1; Kunal Kate1; Sundar Atre1; 1University of Louisville
    Globally research efforts in Additive Manufacturing (AM) are constantly increasing and the knowledge generated through these investigations is immense. These investigations certainly advanced the AM knowledge, but academic institutes/ universities must take the role of transferring this knowledge to students and industries through integration with education. At the same time plethora of scientific knowledge on more than 30 different AM technologies is a big challenge to include in current engineering curricula. In this presentation, we will provide overview of our efforts in integrating AM knowledge with engineering education through capstone projects. This presentation also discusses how the students and industries are benefited through this AM knowledge integration by bringing out innovative products and designs. At the end we will discuss glimpse of additive manufacturing research at Materials Innovation Guild, University of Louisville and how to integrate this engineering education.

10:00 AM Break

10:30 AM  Invited
Hands-on Additive Manufacturing Education for Undergraduate Materials Engineers: Zachary Cordero1; 1Rice University
    Metal additive manufacturing (AM) techniques are an emerging family of processing technologies that undergraduate materials engineers need to become familiar with; however many of these techniques are not amenable to undergraduate teaching labs because they involve dangerous metal powders, high-voltage electronics, intense heat sources, and expensive difficult-to-operate equipment. To overcome some of the practical challenges with introducing undergraduates to metal AM, I have developed a hands-on lab module on hybrid additive manufacturing where students combine 3D printing with traditional metals processing techniques (for example, casting) to create net-shaped objects. This module has been implemented in the undergraduate materials processing class at Rice University and used to introduce key concepts in design for additive manufacturing, solidification processing, and casting practice. This talk will summarize this lab module as well as other educational initiatives related to 3D printing at Rice University.

11:00 AM  Invited
Meta-crystals: Damage-tolerant Architected Lattice Materials and Its Educational Use in Visualising Crystal Microstructure: Chen Liu1; Jedsada Lertthanasarn1; Minh-Son Pham1; 1Imperial College London
    Architected lattice materials are lightweight materials that can exhibit combinations of properties which are inaccessible to conventional solids. However, they have a major issue in that these materials can exhibit a catastrophic post-yielding collapse, causing substantial loss in strength and reduction in energy absorption during deformation. In this study, we present a novel approach in using additive manufacturing to mimic the microstructure observed in crystalline metals to employ key metallurgical hardening mechanisms such as boundary, precipitation and phase hardening to design crystal-like architected materials that are lightweight and extraordinarily damage-tolerant. In particular, we demonstrate substantial hardening can be readily achieved via tailoring polygrain-like, precipitate-like or multiphase-like mesostructures. Last but not least, we will show that crystal-inspired architected materials offer an excellent means in visualising the microstructure in crystals, this significantly assists the teaching and understanding of crystallography and metallurgical hardening in under/postgraduate programmes in materials.