Experimental, Simulation, and Programming-Based Approaches in Additive Manufacturing

What Is Additive Manufacturing?

Additive Manufacturing (AM), widely known as 3D printing, refers to the layer-by-layer fabrication of components using metal, polymer, ceramic, or composite feedstocks. Unlike subtractive processes, AM offers superior design freedom, reduced material waste, and the ability to produce intricate geometries.

Why AM Matters Today

Modern sectors such as medical devices, aerospace, automotive systems, and consumer technology increasingly rely on AM for rapid prototyping, custom part fabrication, and functional end-use components. With ongoing innovations, the field demands professionals who can integrate theory, software tools, and hands-on experimentation.

Digital Design: CAD Modeling and STL Preparation

The Importance of CAD in AM

A successful AM workflow begins with robust Computer-Aided Design (CAD). Participants learn how to create 3D models, optimize geometries, ensure manufacturability, and prepare files suitable for slicing.

STL Preparation and Optimization

Key aspects include:

• Converting CAD models to STL formats
• Repairing mesh defects
• Checking model integrity and watertight surfaces
• Applying slicing strategies compatible with various AM machines

Open-source tools and real-world demonstrations help participants gain practical experience in pre-processing workflows.

Simulation Techniques in Additive Manufacturing

Understanding FEA and CFD in AM

Simulation-driven optimization has become an indispensable part of AM research. The program introduces:

• Finite Element Analysis (FEA): Used for thermal, mechanical, and stress-related investigations.
• Computational Fluid Dynamics (CFD): Assesses gas flow, heat transfer, and material behavior during printing.

Predictive Process Modeling

Participants explore methods to simulate layer deposition, temperature gradients, and residual stress formation. These insights support better material selection, reduced part distortion, and improved build quality.

Metal and Powder-Based AM Technologies

Powder Metallurgy Fundamentals

Metal AM systems often rely on powder feedstocks, making process understanding essential. Topics include:

• Powder characteristics (size, morphology, flowability)
• Sintering and melting principles
• Laser/electron beam-based systems

Applications Across Industries

Metal AM is widely adopted for lightweight aerospace components, lattice structures, high-strength automotive parts, and high-precision biomedical tools.

Biomedical Implant Design and Additive Fabrication

Designing for Biocompatibility

The FDP covers implant modeling concepts such as:

• Contour-matching with anatomical data
• Topology optimization for lightweight structures
• Material selection aligned with biological compatibility

Case Studies

Participants review examples of patient-specific implants and AM-driven medical prototyping to understand real-world applications.

Industry Interaction and Hybrid AM Systems

AM-PravaH Sessions

Industry-focused sessions offer exposure to:

• Expert-led demonstrations
• Industrial workflow insights
• Equipment-level decision-making

Hybrid and Pallet-Based Systems

Hybrid manufacturing—combining additive and subtractive methods—enables precision finishing and complex part creation. The workshop explains system architecture, benefits, limitations, and case examples.

Expected Outcomes of the FDP

By the end of the FDP, learners will gain:

• A holistic understanding of AM processes
• Strong foundational skills in CAD, STL, and simulation workflows
• Exposure to MATLAB-based modeling for AM
• Insights into FEA/CFD-driven optimization
• Knowledge of metal, polymer, and biomedical applications
• Awareness of monitoring and evaluation methods used in AM industries

The training enhances research capability and prepares participants for advanced roles in digital manufacturing and smart production technologies.