ADVANCED MANUFACTURING OF PLASTICS AND COMPOSITES

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 course will be organized into oral lessons and laboratory exercises.

Basic Knowledge of Material Mechanics and Materials Science and Technology

        

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.  

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.

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.

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