TECNOLOGIE AVANZATE PER LA PRODUZIONE DI MATERIALI COMPOSITI E PLASTICI

Academic Year 2025/2026 - Teacher: CLAUDIO TOSTO

Expected Learning Outcomes

The aim of the course is to provide the student with a thorough knowledge on the advanced manufacturing technologies for plastic and composites materials. The student will be first introduced with some concepts and theoretical background on advanced manufacturing techniques for plastics and composites. After this introduction the students will be instructed to gain hand on experience on some of the technologies described theoretically. Among the techniques discussed 3D printing and composite materials will be a special focus for this course. The full access to the equipment’s of the Polymer and Composites Group will be granted to the students at the end of the course to realize some practical projects as part of the final examination.

The skills acquired can be applied in the selection, design, and processing of materials for engineering applications, with attention to sustainability, energy efficiency, and technological innovation, in line with Sustainable Development Goals 7, 9, 12, and 13 of the United Nations 2030 Agenda.

Course Structure

The course will consist of classroom instruction for 3 CFU, and practical exercises (including lab work) for the remaining 3 CFU. The practical exercises will focus on both the use of common 3D printing softwarse and the practical use of 3D printers. Additionally, practical exercises will be conducted on the use of extruders and the manufacturing of composite parts. All lab work will be conducted in compliance with current regulations and/or new health guidelines.

Required Prerequisites

Basic Knowledge of Material Mechanics and Materials Science and Technology

Attendance of Lessons

Attendance is mandatory. It is understood that extensions to this limit are provided for working students.

Detailed Course Content

A) Theory

1a. Additive Manufacturing Techniques for Polymer Materials: Extrusion Additive Manufacturing (FFF, FDM); Photopolymerization (DLP; LCD; LCA; InkJet Printing); Selective Laser Sintering (SLS).

2a. Polymer processing techniques: Extrusion, Injection Moulding, Blow Moulding, Compression Moulding.

3a. Reactive polymer mixing

4a. Thermoset cure kinetic and rheology

5a. Composite production techniques.

B.Practical Experience

1b. Additive manufacturing practice: Setting up the printing process using dedicated software; 3D printing experiments on simple geometries; Examples of 3D printing on complex geometries (case studies)

2b. Extrusion practice: Preparing a binary polymeal mixture; Preparation of a reinforced polymer compound.

3b. Injection molding practice: preparation of samples to "dog bone" or other simple geometry use the formulations prepared in step 2b).

4b) Practice manufacturing fibrer-reinforced materials: preparation of panels, or simple geometries, using the technique of Hand Lay Up or VARTM.

Project: The student will select among some projects proposed by the instructor and will autonomously carry out the design and the experiments.

Textbook Information

The following textbooks are suggested readings only. Slides and papers will be provided to the students during the course.

1) I. Gibson l D. W. Rosen l B. Stucker "Additive Manufacturing Technologies: Rapid Prototyping to Direct Digital Manufacturing", Springer, ISBN: 978-1-4419-1119-3

2) Tim A. Osswald and George Mendez "Materials Science of Polymers for Engineers", Hanser.

3) Raju S. Davé and Alfred C. Loos, "Processing of Composites", Hanser.

Course Planning

	Subjects	Text References
1	Course Introduction	Slides
2	Extrusion Additive Manufacturing	Chapter 6, Book 1 // Slides // Technical Papers
3	Photopolymerization	Chapter 4, Book 1 // Slides // Technical Papers
4	Selective Laser Sintering and Powder Based Processing	Chapter 5, Book 1 // Slides // Technical Papers
5	Extrusion	Chapter Book 2
6	Composites Processing	Slides and Technical papers
7	Thermal Properties: CTE and Thermal Conductivity	Chapter Book 2
8	Thermoset Cure Kinetic and Rheology	Book 3 // Slides // Technical Papers

Learning Assessment

Learning Assessment Procedures

Learning assessment will be based on the completion of conceptual tests (questions to multiple and open answer), realization of practical experiences and case studies; discussion final oral.

To guarantee equal opportunities and in compliance with current laws, students can request a meeting in order to plan any compensatory and/or dispensatory measure, according to the educational goals and specific needs. In this case, it is advisable to contact the CInAP (Centre for Active and Participated Integration - Services for Disabilities and/or SLD) professor of the Department where the Degree Course is included.

Examples of frequently asked questions and / or exercises

Below is an example of a Concept Test.

Which of the following statements best describes the relationship between polymer extrusion AM and conventional polymer forming (e.g., injection molding)?

What materials are typically used in the extrusion additive manufacturing process?

Thermoplastics are considered the primary feedstock for extrusion AM. Thermoplastics can be heated and extruded, molded, or otherwise processed multiple times with minimal material degradation (a requirement for melt-based extrusion). In contrast, the chemical reaction that creates thermoset plastics is not reversible upon heating, which would preclude their use in extrusion processes (although some exceptions exist, such as Massivit3D's process, but this is atypical).

The most commonly used feedstocks for desktop polymer extrusion AM systems are in the form of:

Extrusion is one of the most versatile AM processes, making it suitable for a wide variety of applications. What applications aren't among the most common commercial uses of extrusion AM? Tip: Consider the surface finish, mechanical properties, and other characteristics of extrusion AM-produced parts.

Degree Course in

Mechanical Engineering