E4606 Digital Manufacturing – Spring 2017
Mondays 1:10-3:40, Hamilton Hall room 503
This course examines a variety of digitally-controlled manufacturing processes that convert computer models directly into physical objects. Topics include: Additive manufacturing processes, CNC, Sheet cutting processes, Numerical control, Generative and algorithmic design. Topology Optimization, Broader social, economic, legal and business implications will also be reviewed. Course involves both theoretical exercises and a hands-on project.
On completion of the course, you should
- Be familiar with the product realization process and its documentation (ABET c).
- Be familiar with basic tools of design and manufacturing such as CAD and machine tools. (ABET k).
- Function effectively in a team. (ABET d).
There will be two main projects in this course. In the first, you will design make and sell a physical product online. In the second project, teams of four or five students will design, analyze and build an air motor.
Staffing and office hours:
Instructor: Prof. Hod Lipson, Mudd 535E, email@example.com
Office hours: Tue 3:45-5:15pm, or by email appointment.
TAs: Joni Mici (firstname.lastname@example.org)
Course website: All official course materials and assignments will be distributes through this website
Piazza: Students must use Piazza on the course website for all technical questions and logistical clarification. Direct emails to the instructors should be used only for personal matters
Overview of digital manufacturing processes
- What makes a manufacturing process “digital”
- The 10 disruptive principles of digital manufacturing processes
Additive Manufacturing processes – Engineering polymers, metals, ceramics
- Selective Laser Sintering
- Fused Deposition Modeling
- Layered object manufacturing
Additive Manufacturing processes – Advanced materials
- Electronic Materials
- Food Printing
- Mechanical properties of printed materials
- Post processing
- Empirical and data-driven models
- Laser Cutting
- Plasma Cutting
- Digital Assembly
- Digital Bending
Fundamentals of geometric representations for digital manufacturing
- Solid representations
- Boundary representations
- Function representations
- Voxel representations
Algorithmic design for digital manufacturing
- Parametric Models
- Vibrational Geometry
- Generative models
- Topology optimization
- Gantry positioning approaches
- STL/AMF Slicing
- Safety, Liability and intellectual property
- Environmental impact
- On-demand fabrication models and mass customization
None required. A reading list will be distributed.
Your final grade will be determined from the class activities as follows:
- Lattice design assignment: 10%
- Laser cutting assignment: 10%
- Topology Optimization assignment: 10%
- PCB Milling assignment: 10%
- Food printing assignment: 30%
- Final Exam 30%
Improper, irresponsible or unsafe behavior will result in loss of laboratory privileges in both MechE Lab and the MectTech Lab. Due to the high fabrication content of this course, this policy will be strictly enforced. Grades may also be used to penalize safety.
Students may copy any part of someone else's design work (including from other students, external sources, previous years, the Internet, etc.) but they must explicitly cite the source and provide a complete and full citation. In this case they will be graded on their added value compared to the source. If copying text verbatim, put copied text in quotes and cite source. If paraphrasing someone else's idea, cite original source.
Copying without attribution is considered plagiarism and a violation of academic integrity.
Students with Disabilities
If you are a student with a documented disability on record at Columbia University and wish to have a reasonable accommodation made for you in this class, please contact the instructor immediately.
|Week||Lecture date||Topic||Assigment due on Friday|
|1||Mon, Jan 23||Overview + 10 Principles|
|2||Mon, Jan 30||2D Cutting||Laser box: Design|
|3||Mon, Feb 06||AM Processes (1)||Laser box: Assembled|
|4||Mon, Feb 13||CAD: Generative||Lattice design|
|5||Mon, Feb 20||nTopology||Lattice design: Printed|
|6||Mon, Feb 27||PCB Milling||PCB|
|7||Mon, Mar 06||AM Processes (2)||PCB|
|8||Mon, Mar 13||Break|
|9||Mon, Mar 20||Topology Optimization||Topology optimization|
|10||Mon, Mar 27||Hardware: G-Code, Gantries||Topology optimization|
|11||Mon, Apr 03||Broader Impacts||Food Printing: Square|
|12||Mon, Apr 10||Metal: Material Properties / Future||Food Printing: Pyramid|
|13||Mon, Apr 17||Architecture / Review||Food Printing: Spirograph|
|14||Mon, Apr 24||Final Presentations||Food Printing: Two materials|
|15||Mon, May 01||Final Presentations||Presentations|
|Mon May 8, 1:10-4pm||Final exam (tentative)||See registrar|
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