Educational Programs in Additive Manufacturing

Basic course with accent on AM processing and physical transformations responsible for shaping and properties formation of as-built product.

Academic supervision Dr. Alexander Katz-Demyanetz

Course issues

Introduction and basic principles.
Screening physical processes responsible for microstructure and properties formation of the additively manufactured products.
Additive Manufacturing routes in metallic powders (EBM, SLM).
Additive Manufacturing routes involving extrusion (FDM, binder jetting).
Additive Manufacturing in polymers.
Process selection.
Post-treatments.
Bio-medical and aerospace applications of Additive Manufacturing.
Multi-materials processing routes: composites, hybrid and porous materials.
Future trends: tools design, process analysis, multi-axes systems, new materials’ development.
Products characterization, quality assurance and failure analysis.

Throughout the course a number of practical teaching workshops will be done.

Acceptance threshold conditions

BA/BSc in engineering (mechanical, materials, chemical, building’ environmental, etc.)
Practical experience at least 3 years
Appropriate level in technical English

The widest of the existing courses on AM focusing on processing, materials science and technology issues of AM, machines operating, software, shape optimization, industrial design, laboratory and machines practice, etc.

Academic supervision Dr. Alexander Katz-Demyanetz

Introduction

The interest in 3D printing technologies as a novel manufacturing approach has significantly grown throughout the last two decades. This approach successfully employs 3D computer aided design (CAD) for modelling of manufactured parts by layer-by-layer addition. Production route based on this principle permits to produce parts with high geometric complexity, which cannot be manufactured by any other technique. Thus, geometrically complicated parts can be easily manufactured. The starting point of the additive technologies was the rapid prototyping of polymers-made parts. Today, additive technology is able to produce high-performance metallic parts with superior mechanical and thermal properties. During the last few years, significant efforts have been made to make additive manufacturing (AM) routes industrially applicable. As a result, AM is currently employed in automotive, aerospace, biomedical, food, energy, etc., industries. Due to advantages comparable to the conventional manufacturing routes, AM seems now to be a critical factor initiating the fourth industrial revolution. Considering the mentioned above, importance of the knowledge of the basic principles of AM by engineers’ community becomes clear.    

Basic principles and goals

The main goal of the proposed course is giving to engineers, highly educated in various technological fields, the keys for understanding the basics of AM technologies, governing existing and developing novel AM processes. The issues to be studied are as follows: equipment and its functioning, product building, materials and their processing, melting/solidification/sintering of metals/ceramics/composites, phase transitions and microstructure formation, materials and processes selection, failure analysis and quality assurance.

Target audience

The course is intended to graduates in various fields of engineering, i.e. Mechanical, Materials, Aeronautics, Architecture, Civil Building, Chemistry, Environment, and so on.

Contents

Throughout the course, additive manufacturing approach will be discussed in comparison with those of the conventional manufacturing routes. The necessity of a balance between two main guidelines – shape forming of the product and achieving of the desired properties – will be underlined.

Advanced theoretical issues of materials science and engineering, like diffusion and mass transfer, heat transfer, basics of thermal treating, sintering of metals and ceramics, will be studied. These issues will help understanding mechanisms of formation of desired microstructure and properties throughout AM processing.    

Different issues important for processing parameters, like kind of the heating/melting beam, raw powder particles shape, size and distribution’ temperature, scan speed, hatching distance, etc., will be studied and discussed. Applications for various types of materials – metals and alloys, polymers, ceramics and composites – will be studied. The issue of the post-treatments (heat treating, surface treatment, HIP, etc.) and their effect on the final properties, will be studied. Quality assurance and failure analysis will be also outlined.

Course issues

Introduction and basic principles.
Screening physical processes responsible for microstructure and properties formation of the additively manufactured products.
Additive Manufacturing routes in metallic powders (EBM, SLM).
Additive Manufacturing routes involving extrusion (FDM, binder jetting).
Additive Manufacturing in polymers.
Process selection.
Post-treatments.
Bio-medical and aerospace applications of Additive Manufacturing.
Multi-materials processing routes: composites, hybrid and porous materials.
Future trends: tools design, process analysis, multi-axes systems, new materials’ development.
Products characterization, quality assurance and failure analysis.
Software for AM: Magics, Cura, Creo, etc.
Design and shape optimization for AM.
Designing Architected materials (metamaterials) with the desired material properties (i.e., near zero coefficient of thermal expansion, auxetic metamaterials with negative Poisson’s ratio, custom orthotropic properties, etc.).

Throughout the course a number of practical teaching workshops will be held.

Acceptance threshold conditions

BA/BSc in engineering (mechanical, materials, chemical, building’ environmental, etc.)
Practical experience at least 3 years
Appropriate level in technical English

 
Academic staff

Dr. Alexander Katz-Demyanetz, PhD

Expert in Materials Science, Engineering, Failure analysis and Characterization

Dr. Alexander Katz-Demyanetz had graduated at the Faculty of Materials Science and Engineering at the Technion – Israel Institute of Technology. His BSc graduate work was done on metallic materials and common metallurgy, his MSc thesis was done on ceramic materials, and his PhD thesis was done on composite materials. During last decades, Alexander works as a researcher and a manager of applicative projects in Israel Institute of Materials Manufacturing Technologies of Technion Research and Development Foundation (TRDF). Last two years Alexander works as Knowledge Development Coordinator and Advanced Processes Field Leader of the Institute. Alexander is a Lecturer at Mechanical Engineering Faculty, Civil Engineering Faculty at the Technion (Haifa, Israel) and at Mechanical Engineering Department of Braude Academic College in Karmiel (Israel). Dr. Katz-Demyanetz is an author of numerous scientific publications in materials science and engineering, and a regular participant and organizer of international conferences in his field of expertise.   

Dr. Gary Muller, PhD

Expert in Binder Jetting Technologies

Dr. Muller is a researcher and engineer at the Israel Metals Institute. He specialized as a process development engineer for 3D printing in Koshanan injection (BJP – ExOne M-Flex), 3D printing in an electron beam (EBM – Arcam A2X), 3D printing in a laser beam (SLM/SLS – EOS M290), with 7 years of experience in the field the printing. Dr. Muller is a participant in national and international applied projects in the field of printing, including optimization of the process and the design of the printed product, the main one regarding biomedical applications (titanium implants) and facilities in the field of space (mirrors for satellites). Dr. Muller has more than 10 scientific publications in the field of 3D printing and has teaching and training experience in this field.

Eng. Evgeny Strokin

Expert in Electron Beam and Laser Beam Printing

Head of Metal Printing, Metals Institute, TechnionGraduated from the Faculty of Mechanical Engineering, TechnionSpecializes in optimizing the printing process for various metals, optimizing printing parameters and printing design.Practitioner in the layering processes course for engineers, TechnionCertified operator:EBM electron beam printer.EOS laser printer.

ATO atomizer.

Dr. Natalya Larianovsky

Expert in phase transitions, heat treatment and materials properties formation

Dr. Larianovsky is a graduate of the Faculty of Materials Science and Engineering at the Technion, has 15 years of experience in metallurgical engineering – in steels, light alloys and superalloys, has knowledge of various production processes and is an expert in thermal treatments and characterization of microstructure and mechanical properties of various metals, has extensive knowledge in spectroscopy and electron microscopy. Has 5 years of experience in coatings and surface treatments for biodegradable implants.

Special course focused on AM laser technologies, adjusted for a technical staff employed at metal working plants: technologies, processing, design, materials, quality control.

Special course focused on defense applications of AM laser technologies: technologies, processing, design, materials, quality control.