Advanced Manufacturing Technologies for Composite and Plastic Materials

The course provides students with an in-depth understanding of advanced manufacturing technologies for plastic and composite materials, with particular emphasis on additive manufacturing processes and the main fabrication techniques for composite materials. Through lectures, laboratory activities, and hands-on practical sessions, students will acquire competencies in the design, manufacturing, and characterization of components produced using advanced technologies, while developing an experimental approach to solving engineering problems.

The knowledge and skills acquired can be applied to the design, manufacturing, and processing of engineering materials, with particular attention to sustainability, energy efficiency, and technological innovation, in accordance with Sustainable Development Goals 7, 9, 11, 12, and 13 of the United Nations 2030 Agenda.

Knowledge and understanding

Upon successful completion of the course, students will have acquired knowledge of:

• the fundamental principles of advanced manufacturing technologies for plastic and composite materials;
• the main additive manufacturing processes and composite manufacturing techniques;
• the relationships among materials, manufacturing processes, design, and component performance;
• design and prototyping methodologies based on additive manufacturing technologies;
• the main methodologies for the characterization of materials and manufactured components.

Applying knowledge and understanding

Upon successful completion of the course, students will be able to:

• select materials, manufacturing processes, and fabrication technologies according to design requirements;
• use dedicated software for the preparation of models for 3D printing and the management of additive manufacturing processes;
• manufacture prototypes using additive manufacturing technologies and composite manufacturing processes;
• develop an engineering case study by applying material selection, design, and manufacturing methodologies while working effectively within multidisciplinary teams.

Making judgements

Through laboratory activities, the use of dedicated software, and the development of an engineering case study, students will develop the ability to critically evaluate different technological solutions, select appropriate materials and manufacturing processes according to performance requirements, and justify their engineering decisions by considering technical, economic, and sustainability aspects.

Communication skills

Students will be able to describe manufacturing processes and engineering design choices using appropriate technical terminology, present and discuss the results of laboratory activities and the engineering case study developed during the course, and communicate effectively with specialists in the field.

Learning skills

Students will acquire the skills required to independently update their knowledge through specialized textbooks and scientific literature, follow the continuous evolution of advanced manufacturing technologies for plastic and composite materials, and critically apply emerging technological solutions to the design and production of innovative engineering components.

The course consists of 3 CFU of lectures aimed at providing the fundamental principles of advanced manufacturing technologies for plastic and composite materials, with particular emphasis on additive manufacturing processes, polymer processing technologies, and composite manufacturing processes.

Subsequently, the course includes 3 CFU of practical and laboratory activities, focused on the use of tools and software for the preparation of additive manufacturing processes (e.g. slicing software), the fabrication of prototypes by means of 3D printing, the operation of extrusion equipment, the production of composite components, and the development of an engineering case study. These activities enable students to apply the acquired knowledge to the design, manufacturing, and characterization of innovative components while developing critical thinking, problem-solving, and engineering decision-making skills.

The course is English-friendly: lecture slides and part of the supporting material are also available in English.

If the course is delivered in blended or remote mode, appropriate adjustments may be made to the above in order to ensure consistency with the syllabus.

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.

The assessment of this module consists of two written mid-term tests and an oral examination.

The mid-term tests consist of multiple-choice and open-ended questions covering the topics progressively addressed during the course and are designed to assess students' understanding of the theoretical concepts and their ability to apply them to the manufacturing processes of plastic and composite materials.

Students who successfully complete both mid-term tests are admitted directly to the oral examination, during which they will discuss the engineering case study developed throughout the laboratory activities. The discussion is intended to assess the students' ability to integrate the acquired knowledge in engineering design, material selection, manufacturing process selection, and prototype development.

Students who do not take or do not pass one or both mid-term tests will take a comprehensive oral examination covering the entire syllabus of the module, including the discussion of the engineering case study.

The final evaluation will take into account the student's knowledge of the course contents, the relevance and accuracy of the answers provided, the ability to apply the acquired knowledge to the development of the engineering case study, the ability to establish connections among the different topics covered in the course, the appropriate use of technical terminology, and the overall clarity of presentation.

Learning assessment may also be carried out online, should the conditions require it.

To ensure equal opportunities and in compliance with current regulations, students with specific needs may request a personal meeting in order to plan any compensatory and/or dispensatory measures based on the learning objectives and their individual requirements. Students may also contact the CInAP (Centre for Active and Participatory Integration – Services for Students with Disabilities and/or Specific Learning Disorders) representative of their Department (https://www.cinap.unict.it/content/referenti).

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.