This course provides a comprehensive study of the principles, technologies, and process fundamentals of additive manufacturing (AM) used in modern digital manufacturing. It introduces the evolution of additive manufacturing, its workflow, process classifications, machine architectures, and material and energy delivery systems that enable layer-by-layer fabrication of components. The course covers a wide range of AM technologies, including vat photopolymerization, material jetting, binder jetting, sheet lamination, directed energy deposition (DED), powder bed fusion (PBF), extrusion-based systems, and other advanced manufacturing processes. Learners will explore feedstock preparation, powder production and characterization, process parameters, fusion mechanisms, machine configurations, defect formation, and component evaluation. The course also examines digital manufacturing workflows, Industry 4.0 integration, current research trends, and industrial case studies to develop a thorough understanding of process selection, optimization, and application of additive manufacturing technologies across diverse engineering sectors.

Course Objectives The course is designed to: 1. Provide a comprehensive understanding of the principles, evolution, classifications, and digital workflow of additive manufacturing technologies. 2. Develop knowledge of the operating principles, machine architectures, material delivery systems, energy sources, and process parameters associated with major additive manufacturing processes. 3. Introduce the materials, feedstock preparation techniques, powder production methods, and processing fundamentals required for polymer-, metal-, and ceramic-based additive manufacturing. 4. Equip learners with an understanding of process-specific phenomena, including material fusion mechanisms, process modeling, defect formation, quality evaluation, and process optimization. 5. Enable the selection and comparison of appropriate additive manufacturing technologies based on material characteristics, process capabilities, product requirements, and industrial applications. 6. Foster an appreciation of emerging trends in additive manufacturing, including hybrid manufacturing, Industry 4.0 integration, advanced process development, and research-driven innovations that support next-generation manufacturing systems.