Skip to main content

RajagiriTech: 102907ME631M METAL ADDITIVE MANUFACTURING (102907/ME631M)

METAL ADDITIVE MANUFACTURING (102907/ME631M)

RajagiriTech
Enrollment is Closed

About This Course

Metal Additive Manufacturing has emerged as a transformative technology across aerospace, medical, automotive, tooling, and manufacturing sectors. This MOOC course on Metal Additive Manufacturing provides a comprehensive introduction to the fundamentals and advanced aspects of Metal AM. It begins with an overview of the evolution of manufacturing technologies and establishes the role of AM within Industry 4.0. Learners are introduced to metal AM processes, system classifications, and the advantages and challenges associated with producing metal components using additive techniques.

The course then explores the complete digital workflow—from CAD modelling requirements, mesh repair, slicing, and build orientation to simulation and support strategies. The physics governing metal AM, including melt pool behavior, energy interaction, and microstructure formation, are explained to help learners understand how process parameters influence part quality, defects, and material performance.

Design for Additive Manufacturing (DfAM) forms a major component of the course, enabling learners to apply topology optimization, material selection principles, and structural considerations specific to metal AM. Case studies of optimized real-world components are included to strengthen practical understanding.

The final module introduces modern on-machine sensing and in-situ control systems used for monitoring and improving build quality. Learners study sensor architectures, data acquisition, closed-loop control, and industrial quality-assurance toolkits used in metal AM systems.

By the end of the course, students will gain a strong foundation in digital manufacturing, design strategies, and process control for Metal AM, equipping them for advanced study or industry application in smart metal manufacturing.

Prerequisite

102907/ME401M- Additive Manufacturing

Course Staff

Staff Member 1: Lt. Dr. Vishnu Sankar

Biography of instructor/staff member:

Lt. Dr. Vishnu Sankar completed his Ph.D. in Thermal Engineering (2023) from CUSAT, M.Tech in Thermal Engineering (2015) with 3rd Rank in aggregate from CUSAT University and B.Tech in Mechanical Engineering (2013) with 7th Rank in aggregate from CUSAT University. Dr. Vishnu, who began his teaching career in 2015 at Holy Kings is currently working as Assistant Professor in Department of Mechanical Engineering at Rajagiri School of Engineering and Technology, Kakkanad from June 2016. He is an approved Research Guide for Doctoral Studies at APJ Abdul Kalam Technological University. Lt. Dr. Vishnu Sankar successfully completed three months Pre-Commissioned Course (PRCN) training conducted from 29th July 2024 to 9th October 2024 @ Officers Training Academy, Kamptee, Nagpur, India and commissioned as Associate NCC Officer with a rank of Lieutenant in the Army wing. Dr. Vishnu Sankar won Gold Medal (First Prize) in Inter COMPANY CHAMPIONSHIP @ Officers Training Academy, Kamptee. He Judged CBSE Regional level Science Exhibition 2016, SAE Mahindra AWIM 2019 JET TOY Competition, Crossroads-15, Crossroads-17 and Crossroads-19. Dr. VISHNU SANKAR (KTU-F20551), Assistant Professor, MECHANICAL ENGINEERING, RAJAGIRI SCHOOL OF ENGINEERING & TECHNOLOGY is an approved Ph.D. Research Supervisor of APJ ABDUL KALAM TECHNOLOGICAL UNIVERSITY from 15/10/2024. The Supervisorship is approved vide University Order No.U.O.No.2606/2024/KTU Dated 27/08/2024. He has published and presented several research papers in the various national and international journals, conferences and seminars, besides having been part of the various funded research projects. He also have 5 granted Patents to his credit. He has more than 232 Google Scholar citations with h-index 7, Research Interest Score of 105.8 and ResearchGate Score of 12.03. He won the "Best Student Award" of Chinmaya Vidyalaya for academic year 2008-2009. He is a Life Member of The Institution Of Engineers India (IEI), The American Society of Mechanical Engineers (ASME) & Indian Society For Technical Education (ISTE). He is one among the ASNT International LEVEL 2 Certified Mechanical Engineer in Ultrasonic Testing, Magnetic Particle Testing, Liquid Penetrant Testing, Radiographic Testing and Radiographic Film Interpretation. He is also one among the National Council for Technology and Training (NACTET) Certified Professional in QA/QC Engineering, Piping Inspection, Project Management, Welding and Oil & Gas. He was Observer under National Testing Agency (NTA) of Government of India Exam for NEET 2023 & 2024 and CUET (PG) 2025 exams. He was also Expert panel member (Evaluator) for the Young Innovators Program (YIP) 4.0 & 6.0 organized by Kerala Startup Mission in association with Kerala Development and Innovation Strategic Council (K-DISC) and Expert Commissioner for District Consumer Disputes Redressal Commission, Ernakulam. His Area of Research interest includes Coatings in I.C Engines, Biodiesel production & testing in I.C Engines, Thermodynamics and Thermal Engineering. He is also one among the few candidates who qualified NPTEL Online Certification course on THERMODYNAMICS by IIT Kharagpur with Elite category certificate, Latex Online Certification course offered by the Spoken Tutorial Project by IIT Bombay, ASME Online course on Standards & Certification and online certification courses offered by Coursera.

 Syllabus

Module 1: Introduction to  Metal Additive Manufacturing

Evolution of manufacturing technologies- Definition and workflow of additive manufacturing -Classification of AM processes - Comparison of AM with subtractive and formative manufacturing - Advantages, limitations, and industrial applications - Overview of metal additive manufacturing - Introduction to the metal additive manufacturing - Classification of metal additive manufacturing and challenges associated with it – Applications of metal additive manufacturing – Various terms associated with metal additive manufacturing.

Module 2: CAD and Digital Workflow for AM

CAD modelling requirements and file formats (STL, AMF, 3MF) - Data repair and mesh optimization - Build orientation, slicing, and support generation - Process simulation and error compensation - Design considerations in additive manufacturing - Machine setup - Integration of CAD–CAM–CAE in AM workflow - Design Process for 3D Printing.

Module 3: Metal AM Processes and Physics

Overview of metal AM processes and classification - Laser and Extrusion-based systems: Powder Bed Fusion (PBF) - Filament, Powder, and Sheet systems: feedstock characteristics and machine design - Directed Energy Deposition (DED), Binder Jetting, and Material Jetting - Process physics: energy interaction, melt pool dynamics, solidification, and microstructure formation - Process parameters and their influence on density, defects, and surface finish - Emerging Metal AM Processes.

Module 4: Design Strategies for Metal AM

Design for Additive Manufacturing (DfAM) and topology optimization - DfAM fundamentals and principle - DfAM design making and application field - DfAM techniques and steps, DfAM case study with example - Design optimization, material selection, and consideration in DfAM - Case studies on optimized metal AM components - Scope of improvement and scope of future research.

Module 5: On-machine sensing & In-Situ Control System in Metal AM

Introduction to sensing machine - Common terms - Basic principle for on on-machine sensing - Factors affecting on on-machine sensing - Spatially integrated sensors - Spatially resolved sensors - Data gathering level - On-machine sensing architecture - In-Situ Control System - Process control - Control objectives - Quality control in AM chain - Feedback control - Commercial toolkits for PBF process - Challenge and opportunities in process control.

Course Summary

  1. Course Number

    102907ME631M

  2. Classes Start

  3. Classes End