Course content

With the topic Rapid Manufacturing (RM) it is deepened into the main factors for the acceleration and efficiency improvement of advanced fabrication processes for subtractive, additive and forming manufacturing as for instance High Performance Machining, Direct Metal Object Fabrication (DIMOF) and Incremental Sheet Metal Forming (ISMF) together with their integration into modern time-compressing engineering methods like Design for Manufacturing, Applied Nonlinear Optimisation, Concept and Concurrent Engineering, Geometric Reverse Engineering, manufacturing data generation and exchange, Closed Quality Loop Manufacturing. Theoretical basis and necessary Information and Communication Technologies (ICT) for the active utilisation of both hardware and software applications including real-world examples from selected application areas accompanied with practical laboratory works/projects, especial in DIMOF with the application of the Selective Laser Melting (LaserCUSING) process. Platform establishment for Hybrid Manufacturing joining subtractive, additive and forming fabrication processes for the make of a complex workpiece, often personalised. Further actual Research and Development problems are being discussed reflecting the international and national state of the art.

Learning outcome

Knowledge:
(i) The definition of RM and its enormous value-adding potential, especially for tool making industries
(ii) RM theoretical concepts (e.g. duality in manufacturing, applied optimisation, acceleration measures providing time compression with Rapid Prototyping & Rapid Tooling as further core areas of RM)
(iii) RM survey of main fabrication processes (e.g. sheet-metal forming, additive (Direct Metal Object Fabrication (DIMOF) with exercises), subtractive (High Performance Machining), and hybrid manufacturing processes
(iv) Survey of RM-applied materials
(v) RM data creation (Direct Engineering Product Development, Geometric Reverse Engineering)
(vi)RM data exchange and ICT systematisation
(vii) RM work piece finishing procedures covering subtractive, additive and sheet-metal forming processes
(viii) RM close-to-manufacturing Quality Assurance
(ix) Project work as contribution for problem-based learning by doing.
Skills:
(i) Theory and practice in manufacturing-adapted RM methodologies for the fabrication of sophisticated free-form objects (with the focus on tool making).
(ii) Experiences with selected hardware and software tools for being able to contribute actively to problem solutions for manufacturing accelerations and bottleneck avoidances.
(iii) Conduction of fabrication tasks utilising subtractive, additive and (sheet metal) forming processes
(iv) Suitable result representation in the customer-directed problem area language
(v) Written project work in specialised English
(vi) Training in oral project presentation in specialised English (voluntary).
General competence:
(i) Overview about and insight into selected theoretical and practical matters of RM as well as industrial applications
(ii) Understanding RM as key Production and Quality Engineering methodology, as vital component of value-adding manufacturing processes
(iii) Abilities for minimise waste in all manufacturing activities, and for better utilisations of resources in work force, material, energy, time, information, etc.
(iv) Application capabilities of relevant ICT support routines (e.g. E/CAD/CAM/CAQ, Geometric Reverse Engineering, applied non-linear optimisation)
(v) Research-based treatment and professional presentation of relevant RM matters with national and international profile.

Learning methods and activities

Lectures, international guest lectures, exercises, and laboratory work/exercises, mainly in the DIM laboratory and the PC laboratory as well. One colloquium and project work. The course requires an accepted project report. The project work documented by the report gives 50 % of the final grade. The course is given in English. In case that not only Norwegian students are participating in the course, the exam text will be given in English only. For a make-up examination necessary, the examination form may be changed from written to oral.

Compulsory assignments

• Exercises
• Project work

Recommended previous knowledge

Basic knowledge in systems thinking, multivariate mathematics, computer programming and knowledge corresponding to TPK4105 Manufacturing Technology.

Course materials

KOCH, W. H.: "Rapid Manufacturing". Lecture Notes. Trondheim, 2013. Selected papers from scientific journals.