Birla Institute of Technology & Science, Pilani

Work Integrated Learning Programmes Division

High Precision Manufacturing
Digital Learning Handout

Course Title Design for Additive Manufacturing

Course No(s) DE ZG544/ DM ZG521
Credit Units 5
Credit Model 4+1=5
Instructor-In-Charge JAYA PRAKASH SHARMA
Version Number 1
Date 08/01/2021

Scope of the course:

The course is meant for the manufacturing engineers who have limited expertise in design tools. The
course gives an overview of computer aided design, part modelling and analysis using contemporary
tools. The course focuses on design for manufacturing and assembly in particular the additive
manufacturing. The key topics to be covered are, design considerations for additive manufacturing,
support structures in metal-based systems and lightweight structures.

Course Objectives:
 Become familiar with DfAM guidelines and best practices
 Design, redesign, and optimize products by using DfAM.
 Explain the ways DfAM can be used to add value including light weighting, part consolidation and
complex internal geometries.
 Define the available materials and processes and determine the factors which influence their
suitability for a given design.
 State the opportunities for Reverse Engineering in AM.
 Identify the uses of simulation in Design for Function and Design for Manufacturability in AM.
 Recognise the file types, data workflow and possible upcoming changes to AM digital thread.
 Compare the overall workflow of DfAM with conventional manufacturing.

Text Book(s):
T1 3D Printing - Understanding Additive Manufacturing: Andreas Gebhasrdt, Julia Kessler, Laura
Thurn
T2 The 3D Printing Handbook - Technologies, design, and applications: Ben Redwood, Filemon
Schoffer, Brian Garret
T3 Additive Manufacturing of Metals: The Technology, Materials, Design and Production: Li Yang,
Keng Hsu, Brian Baughman, Donald Godfrey, Francisco Medina, Mamballykalathil Menon, Soeren
Wiener
T4 Diegel O., Nordin A. and Motte D., A Practical Guide to Design for Additive Manufacturing,
 Springer, 2020, Singapore.

Experiential Learning Components:

1. Lab work: Ansys Additive Simulation Lab
2. Assignment: None
3. Project work: None.
4. Case study: None
5. Work integrated Learning Exercise: None
6. Design work/Field work: None.

Content Structure:

Reference
Sessions Learning Objectives Topics
Textbook
Overview of AM Introduction to AM, Advantages and
1 technologies from design Disadvantages, Process Chain, T1
point of view Applications, Materials

2
Determining optimal 3D
3 Printing process and Classifications of AM: Principle,
material based on the Printer Characteristics, Dimensional
4 T1, T2
specific design best Accuracy, Materials, Post Processing,
5 suited to their Benefits and limitations, Applications;
applications
6
Quick reference design Decision Making tools for all
7 T2, T3, T4
guidelines technologies

General design consideration for AM:

Quick basic Design
8 Layer height, shrinkage and warping, T2, T4
Information
Support structure, Fillet
Learning to print the part
Designing for FFF: Support Structure
successfully, designing a
9 and part orientation, Type of support, T2, T4
parts for chosen AM
Anisotropy, Infill, Hole, Design Table
technology,
Understanding Designing for SLA/DLP: Support
10 actionable design advice structure and part orientation, Hollow T2, T4
for designers and section, Design Table
engineers for each
technology, Designing for SLS: Shrinkage and
11 Understanding warpage, over-sintering, powder T2, T4
Printability issues in the removal, stepping effect, Design Table
12 design, and Allow to Designing for Material Jetting: T2, T4
produce the parts as per Support structure and part orientation,
the specifications. Multi-material Integration, Design
Table
 Designing for Binder Jetting: Binder,
13 Green state, Full color print, T2, T4
Infiltration and sintering, Design Table

Designing for DMLS/SLM: Support

and part orientation, hollow section,
14 T2, T4
build plane, skin and core, common
design parameters, Design Table.

15 Methods for DfAM and

Topology Optimization, Latticing, Part
Overall summary for T2, T3, T1, T4
16 Consolidation, Design Rule Summary
DfAM

Evaluation Scheme:

Legend: EC = Evaluation Component; AN = After Noon Session; FN = Fore Noon Session

Evaluation Name Type (Open Weight Duration Day, Date, Session, Time
Component (Quiz, Lab, Project, Mid- book, Closed
term exam, End semester book,
exam, etc.) Online, etc.)
Assignment Online 10% 10 days August 16-30, 2022
EC - 1
Virtual Lab Online 20% To be announced
EC - 2 Mid-Semester Test Open Book 30% 2 hours Friday, 23/09/2022 (AN)
EC - 3 Comprehensive Exam Open Book 40% 2 hours Friday, 25/11/2022 (AN)

Syllabus for Mid-Semester Test (Open Book): Topics in Contact Hours: 1 to 16

Syllabus for Comprehensive Exam (Open Book): All topics
Important links and information:
E-learn portal: https://elearn.bits-pilani.ac.in
Students are expected to visit the E-learn portal on a regular basis and stay up to date with the latest
announcements and deadlines.
Contact sessions: Students should attend the online lectures as per the schedule provided on the E-learn
portal.
Evaluation Guidelines:
1. EC-1 consists of either two Assignments or three Quizzes. Students will attempt them through the
course pages on the E-learn portal. Announcements will be made on the portal, in a timely
manner.
2. For Closed Book tests: No books or reference material of any kind will be permitted.
3. For Open Book exams: Use of books and any printed / written reference material (filed or bound)
is permitted. However, loose sheets of paper will not be allowed. Use of calculators is permitted
in all exams. Laptops/Mobiles of any kind are not allowed. Exchange of any material is not
 allowed.
4. If a student is unable to appear for the Regular Test/Exam due to genuine exigencies, the student
should follow the procedure to apply for the Make-Up Test/Exam which will be made available
on the E-learn portal. The Make-Up Test/Exam will be conducted only at selected exam centres
on the dates to be announced later.
It shall be the responsibility of the individual student to be regular in maintaining the self-study schedule
as given in the course handout, attend the online lectures, and take all the prescribed evaluation
components such as Assignment/Quiz, Mid-Semester Test and Comprehensive Exam according to the
evaluation scheme provided in the handout.

Instructor-in-charge

(DM ZG521)
 Design for Additive Manufacturing (DfAM) DMZG521 Lab
Course Handouts

Faculty Name, J Jayakrishnan

Email Id & Contact
jkrishnan@wilp.bits-pilani.ac.in
Details
9562228686

Contents
1. Scope of Lab
2. Objective of Lab
3. Learning Outcomes of Lab
4. List of Tasks/Experiments
Software Tool Used: ANSYS Workbench, ANSYS Additive, Autodesk Fusion 360, Ultimaker
Cura
5. Instruction Schedule
6. Evaluation Scheme

Scope of Lab
 To understand the theory learned in the Design for Additive Manufacturing course
(DMZG521) and to implement the theoretical knowledge by redesigning the parts using
Topology optimization and understand the process of creating multiple design variants
using generative design. After designing, the designed part will be validated by process
simulation using ANSYS Additive Print and Additive Science for a successful printing of
parts. Then finally the process planning in Fused Deposition Modelling process will be
taught using Ultimaker Cura.

Objectives of lab
 To develop skills which will help students to model or design a part for AM process
based on Design for Additive Manufacturing (DfAM) rules.
 To understand the process chain in AM process and to mitigate the issues faced in AM
process by designing or modelling the part accordingly.
 To understand the process induced errors in the part during manufacturing (Distortion,
collision with the recoating blades)

Learning outcomes
 To understand and perform shape & topology optimisation on a given part using
commercial software.
 To understand process planning in 3D printing using open-source software.
 To validate the part design before the actual printing is done through proper process
simulation.
List of Tasks/Experiments:

Tutorial Tutorial Name Remote Lab Type

Number Lab
 Introduction to generative design Own laptop/PC
1
 Generative Design using Autodesk Fusion
360
 Introduction to ANSYS Workbench Own laptop/PC
2
 Topology optimisation using ANSYS
Workbench 20 marks
 Influence of process parameters in FDM Own laptop/PC
3
 Process planning for FDM using Ultimaker
Cura
 Design assessment using ANSYS Additive Remote Desktop
4  Simulation on Additive Print
 Simulation on Additive Science

Instruction Schedule

For lab calendar in terms of practice sessions, lab exams and other instructions please use the
following link:
https://drive.google.com/file/d/1KcG4tnpkKMQ8FWtBHd7Uf6zZMkoQs_Dt/view?usp=sharing

NOTE: Any changes in lab schedule, evaluation component or other changes related to EC-1 will
be informed by theory or lab instructor.

Instructor-in-charge

(DMZG521)