Sample Lab Activities - Community College of Philadelphia



COMMUNITY COLLEGE OF PHILADELPHIACourse DesignationASET 140 Course Title3D Printing—Additive ManufacturingAbbreviated Course Title for Banner3D PrintingDivisionMath, Science and Health CareersDepartmentPhysicsCourse DescriptionAdditive manufacturing (AM), also referred to as 3D printing, is a process of creating objects by building them up layer by layer. This course will provide hands-on experience with 3D printers as well as introduce applications of AM in the manufacturing sector. This course may be applied to the Applied Science and Engineering Technology degree, and may be of interest to students in other curricula.Prerequisites/CorequisitesFNMT 118 or higher MATH with a grade of C or better or placement in MATH 161 or higherPlacement ENGL 101 Ready Hours and Credits3-3-4Class size (maximum)24Programs where this course appearsApplied Science and Engineering Technology (ASET)Course Writer(s)Randy LibrosContributor(s)Ed Graham (industry consultant)Facilitator (s)Recommended Starting SemesterFall 2019Course Revision or New CourseNew CourseIf this is a course revision, indicate which are being revised (check box)?Prerequisite(s)?Course Title?Course Description?Credit Hours?Student Learning OutcomesCourse AttributesNoneDateSeptember 26, 2018A. RationaleThe impetus for the development of this course grew out of an industry focus group exploring the need for a nanotechnology program at the technician level. The focus group was organized as part of the College’s involvement with the National Science Foundation’s National Nanotechnology Coordinated Infrastructure (NNCI) initiative, wherein the College is a subcontractor with the Singh Center for Nanotechnology at the University of Pennsylvania. Important findings from the focus group include the increased use of additive manufacturing for the manufacture of final products and the incorporation of additive manufacturing to enhance more traditional forms of subtractive manufacturing, such as computer numeric control (CNC). Additive manufacturing (AM) has been described “as revolutionizing product development and manufacturing . . . . and that we are experiencing a new industrial revolution. AM is now frequently referred to as one of a series of disruptive technologies that are changing the way we design products and set up new businesses.”As additive manufacturing increasingly finds its way into manufacturing industries, there will be a growing need for individuals with some background in additive manufacturing. The course is a technical elective in the Applied Science and Engineering Technology (ASET) program. Including this course as a technical elective will provide students with knowledge and skills in an important emerging technology in manufacturing, which is consistent with the overall goals of the ASET program. B. Student Learning Outcomes and Methods of AssessmentStudent Learning OutcomeUpon successful completion of the course, students will be able to:Method of AssessmentDefine terms and acronyms related to additive manufacturing and identify or explain basic concepts of 3D CAD files and the .stl file formatQuiz or exam questions Describe basic concepts of the manufacturing process and the ways in which additive manufacturing is affecting and transforming manufacturingQuiz or exam questions Case study Solve problems related to volume, area and basic geometric shapesQuiz or exam questionsPerform unit conversions between US customary and International System UnitsQuiz or exam questionsDefine current additive technologies (currently this includes technologies such as SLA, SLS, FDM, and high speed sintering) and compare and contrast their uses in various applicationsQuiz or exam questionsProject Differentiate between industrial and consumer equipment in relation factors such as materials, print quality, and post processing, Quiz or exam questionsDescribe procedures for setting up an AM part run.Project Explain the importance of instrument calibrationQuiz or exam questionsPractice safe work procedures in the labObservation of student activities in labCorrectly utilize basic measurement devices such as calipers, micrometer, scale.Lab activity Perform basic setup, change over, and maintenance of equipmentLab activity Demonstrate basic ability to manipulate 3D printing files for part placement, capture of part mass properties: volume, xyz dimensions and surface area.Lab activity Fabricate a part using AM equipmentLab project where students will 3D print a specific objectC. GradingThe following is an example of how instructors might weight each graded element in the course. Instructors may modify this grading scale. The department sets the weight of labs at 20% of the grade, provided that students pass the lab. Failure of the lab will result in failure of the course. Quizzes20%Exams20%Labs20%Project20%Final Exam20%Total 100%D. Planned Sequence of TopicsBelow is a suggested topical outline of course content. Instructors will need to have some flexibility in presentation of these topics, both in the order of presentation as well as content, given the rapid changes that are occurring with this technology. For example, if a new 3D printing process emerges, or an existing one becomes less commonly used, the instructor should be free to adapt the content to the current technology. While there is some flexibility in the topic outline, all of the student learning outcomes must still be addressed. Introduction to the Manufacturing process and Additive Manufacturing (AM) (SLO 1,2)Basic concepts of the manufacturing processBasic Concepts of how AM worksApplications in manufacturingHow AM is changing the nature of manufacturingTerminology and acronymsSafety issues related to AM/lab safety (SLO 9)3D visualization and conversions (SLO 3,4)Unit conversionsReview of basic geometry: area, volume, basic geometric shapesThree dimensional shapes, such as cubes, pyramids, cylinders, cones, etc.The xyz coordinate systemPlacement and orientation of 3-dimensional objects in a 3-dimensinal coordinate systemAdditive Manufacturing processes with focus on FDM (5,7,11,12,13)Conceptualization and CADSTL and AMF filesTransfer of files to AM machine; file manipulationMachine set up and BuildRemoval and cleanupPost processingOther AM approaches; advantages and disadvantages of different technologies (SLO 6)Vat PhotopolymerizationPowder Bed FusionMaterial jettingHigh speed sinteringApplications for Additive Manufacturing: case studies of how AM is changing manufacturing (SLO 6)PrototypingAM in the design processAM in the manufacturing processE. Student Learning Activities and AssignmentsMultiple types of learning activities should be incorporated in order to address the student learning outcomes from a variety of approaches. The instructor is free to modify the list of activities as long as all learning outcomes are addressed.Lecture/Demonstration. The introduction of new ideas will involve lectures and demonstrations, which will provide a context for each topic, an explanation of new terminology and new concepts, and examples of industry applications. Lectures and demonstrations will be important to address all learning outcomes, including those that will eventually require laboratory assessment. Laboratory. Students will meet in lab each week in order to gain hands-on experience with 3D printing processes. In addition, laboratory experiments are designed to reinforce important concepts covered in lecture. Please see the Appendix for example lab assignments. Laboratory activities, including the lab project, will be important to address all learning outcomes and will be specifically used to assess Student Learning Outcomes 7, 9-13.Exams and Quizzes. Student learning will be reinforced and assessed through quizzes and exams. An example quiz can be found in the Appendix. Quizzes and exams will be used to assess Student Learning Outcomes 1- 6 and 8.Homework Assignments. Weekly assignments will be designed to reinforce fundamental concepts and help prepare students for quizzes and exams by providing practice in addressing a variety of concepts and problems, as well as reinforcing proper use of terminology. Homework problems will generally be selected from the textbook. After students have had the opportunity to attempt homework problems on their own, selected problems will be reviewed in class on an as-needed basis. Additional problems may be assigned in class during lecture to help students gain an understanding of approaches to solving certain kinds of problems prior to attempting them at home. This activity will be important to address all learning outcomes, including those that will eventually require laboratory assessment.F. Required and Optional Texts/Readings/MaterialsThe following textbook is recommended as a required text for this course:Gibson, I., D. Rosen, & B. Stucker. (2015) Additive manufacturing technologies: 3D printing, rapid prototyping, and direct digital manufacturing (2nd ed.) New York, NY, Springer.The book was recommended by the Technician Education in Additive Manufacturing & Materials (TEAMM) project based at Edmonds Community College in Lynnwood, Washington and has the advantage of providing clear introductory material, broad coverage of a range of additive manufacturing technologies, as well as end-of-chapter problems. If another textbook is selected for the course, it should contain the same range of material and homework problems as the recommended text.There are also a number of resources available online that may be useful to students. Links can be provided on Canvas, and instructors can decide which online resources to make required or supplementary material. A few examples of online material are listed below:What is 3D Printing? A definitive guide to additive manufacturing. This resource is provided by 3dhubs, a commercial site based in the Netherlands. The link includes a great deal of basic information about advantages and disadvantages of additive manufacturing, different materials that are used, and different additive manufacturing technologies. The guide also includes links to additional resources. It can be found here. Several modules directly related to course outcomes are available on the MatEdu web site. The modules include a detailed topic outline and presentation material, as well as related activities. The modules can be accessed here (note that one may need to create an account to view material details).Additional modules, though not as detailed as the MatEdu modules, are available from the web site of Technician Education in Additive Manufacturing and Materials (TEAMM) at: Thingyverse is a web site that provides a large number of 3D printable projects of varying levels of difficulty. Print files can be downloaded directly from the web site: . Resources Needed for This CourseIn order to successfully run this course, the following resources will be required:3D Printers. Initially there will be enough funding available from the NNCI grant subcontract through the Singh Center for Nanotechnology to purchase 3D printers to run the lab. The cost of 3D printers has come down significantly, and it is possible to purchase machines that will be appropriate to the course at a unit cost of $1,000 or less. As the number of students who opt to take this course increases, there may be the need to purchase additional printers.Depending on the specific printers we purchase, we may need to also purchase SD card readers for the computers that are in the lab. SD Card readers are available for $10.00-$20.00 each. Often SD cards come with printers that require them, but if additional SD cards are required, they can be purchased for under $25.00 each. While it is not anticipated that the course will require use of any 3D modeling software, if it is later determined that such software would be beneficial for the course, there is free, open source software available for that purpose. One example is OpenSCAD, a 3D modeling software that was specifically designed for creating 3D models that could then be printed. This software is available free at: AppendixSample Lab ActivitiesBelow are general descriptions of three possible lab activities that highlight some important factors related to additive manufacturing. LAB #1Title: Part build orientation—Money ClipDescription: One benefit of 3D printing is that you have almost limitless possibilities on what you can create. If you have a 3D CAD file, you can create a part. The ability to print a part does not mean that it yields the best result for the given application. Every part geometry will have an orientation that will yield the best results for the given application or agenda.Purpose: The objective of this lab is to observe the effect build orientation has on several key factors. Assignment: Download the file for building a money clip: up the part on a 3D printer and position in two different build orientations. Build each orientation separately. At the end of each build, observe and test the performance of the two different money clips.Observations to be made: Impact on build success rate – did they both build successfully?Impact of part quality –- did one orientation yield a better print quality?Impact on build time – did one take longer to build? (Parts have the same geometry –volume and surface area but different print time)Impact on supports required and the effect on the post processing – was one harder to clean supports?Impact on part strength – load cards or paper into each clip and see if you can open one more than the other before failure.LAB #2Title: Part build styles—cuboid Description: A significant benefit of 3D printing allows you to reduce the weight of a part you are manufacturing. Adjusting parameters within a machines software will allow for variations in the infill %. However, there is a tradeoff between strength to weight ratios for any given application. Building a large part could yield a part that is very heavy. Having the ability to honeycomb a part to reduce weight can be a major benefit.Purpose: The objective of this lab is to observe the effect of different build styles and how it affects the characteristics of the final part.Below is an example of how the inside of an object might look with different fill percentages. Assignment:Download the file: up the part on a 3D printer. Build three test specimens separately. Assign a different infill % for each of the parts – solid (100%), 50% and 25%.Observations to be made:Impact on build timeImpact on part weightImpact on part strength – in direction of build versus transverse.LAB #3Title: Materials—Chip bag clipDescription: One benefit of 3D printing is the ability to quickly change the material used to make a part. Taking advantage of the process allows you to print parts in different materials and colors. Traditional manufacturing focuses on producing parts from the same material for every part. Purpose: The objective of this lab is to learn how to change materials on a 3D printer and to observe the effect of different materials on a part in several key areas. Assignment:Download the file: up the part on a 3D printer. Build a part in PLA and also in ABS.Observations to be made:Impact on build timeImpact on part weightImpact on part strength – is one easier to flex open?Impact on heat deflection – take each part and place in hot tap water and observe after 1 minute – does one have better integrity after?Impact on cost/print for each part – did one print faster; was material cost more expensive for one?Sample QuizASET 140Quiz # XXXName ______________________Please read each question carefully and answer completely. For multiple choice items, select the best answer. For problems, you must show your work to receive credit for your answer. In which of the following processes is a thermoplastic filament melted?SLAFFMFDMSLSBoth b and c are correctWhat is the major difference between “additive manufacturing” and “subtractive manufacturing”?37241924140946Given the xyz coordinate system shown to the right, properly label the +Y axis and +Z axis so that this is a right-handed system. Explain the difference between “build platform” and “build surface”. Final ProjectThis project will span both lecture and lab and should be carried out over 4-5 weeks.Part 1: With approval of the instructor, student will select an object to print from the web site. Student will then develop a plan for how the object will be printed, specifying print scale, orientation, fill, and other parameters. Plan will also include why or why not there is a need for support during the build process, and what post-processing might be required. Part 2: Student will work in a group where members of the group review and critique each other’s project plan. Student will revise the plan, as needed, and submit to the instructor.Part 3: Instructor will review the plan and provide feedback to the student, including any suggestions for modifications. Student will modify the plan as needed.Part 4: Student will print the object, based on the plan.Part 5: Student will write a report of the outcome of the printing process. The report should include measurements to determine if the dimensions of the object are accurate, the overall success of the printing process, and suggestions for how the process might be improved. ................
................

In order to avoid copyright disputes, this page is only a partial summary.

Google Online Preview   Download