Registration and Course fees

Interested participants should pre-register at the

earliest by sending an email to the coordinator
(karuna@iitb.ac.in) along with their designation
and contact details. This shall be shortly followed by
the formal registration along with the course fee.
The number of participants will be limited to 30.
The participation fee is Rs. 20,000 for industries.
The fee for academic institutions and DRDOs &
OFs will be Rs. 15,000 (including Service Tax of
12.36%). Please add a processing charge of Rs. 100
on outstation cheques. The course fee in the form of
either a bank draft or a cheque drawn in favor of
The Registrar, IIT Bombay CEP A/C may be
sent to the coordinator.

VENUE:
MAIN GUEST HOUSE,
IIT BOMBAY
DURATION:
3 DAYS
FEB 19-21, 2014
COORDINATOR:

PROF. KARUNAKARAN
MECHANICAL DEPARTMENT

The participants will receive a nice course kit that

includes a detailed book on Rapid Product
Development & Manufacturing compiled by the
coordinator. Lunch and refreshments will be
provided during the course. Participants must make
their own arrangements for travel and stay. A limited
number of them can be accommodated in our Guest
House on payment.

FOR FURTHER INFORMATION PLEASE

Dr. K.P. Karunakaran

Department of mechanical engineering,
Indian Institute of Technology,
Powai, Mumbai 400076
Tel: 022-25767530/4508
E-mail: karuna@iitb.ac.in
Professor-in-Charge
Continuing Education Program
Indian Institute of Technology Bombay
Powai, Mumbai-400076
Tel : 022-5767060 Email : cep@iitb.ac.in

Indian Institute of Technology

Continuing Education Program
Feb 19-21, 2014

CEP Workshop
on

3D Printing
and Allied
Technologies

Targeted Audience

Course Coordinator

This workshop aims at helping

Working professionals and industrialists appreciate the
significance of RP&M.
Keen participants will be able relate these technologies
to their work and apply them appropriately to cut down
the product development and manufacturing cycle
times. In order to reap the full benefits of this course,
the participants should be graduate engineers or
experienced diploma engineers.
This course will help college teachers identify research
areas that have immediate industrial applications. The
participants are encouraged to use their spare time
during the course to explore ways of exploiting the
facilities and skills across the institute for mutual
benefits.

Dr. K.P. Karunakaran has 27 years of professional experience. He worked in Hindustan Aeronautics
Ltd. for 8.5 years in the areas of CNC machining and process planning. He joined the Department of
Mechanical Engineering at the Indian Institute of Technology Bombay in 1994. He was a consultant
to Mercedes-Benz Technology Centre, Stuttgart (Germany) in summer 2000 and to VicomTech, San
Sebastian (Spain) in summer 2003. He was a Visiting Professor in the University of Metz in France
in winter 2005 and in Ecole Centrale de Nantes in France in Winters 2006, 2008, 2009 & 2010. He
has association with Fraunhofer institutes since 1998 through summer visits (1998, 2002 & 2006) as
a Humboldt Fellow.
He developed OptiLOM, a pre-processor for LOM-RP in collaboration with
DaimlerChrysler and Materialise and launched it as a module of Magics during EuroMold 2002.
Rapid Manufacturing of metallic objects and optimization of machining through geometric and
mechanistic simulation are his research interests. He has developed a GMAW-based Hybrid Layered
Manufacturing (HLM) process. Department of ICT has funded this research to the tune of Rs. 3
crore. Techno-economic viability of HLM has been established for dies and molds and is ready for
commercialization. Economic manufacture of composite injection molds with conformal cooling
ducts using discrete adaptive deposition is a unique capability of HLM. HLM is being extended for
components using a Hermle C30U 5 axis platform. Dr. Karunakaran has developed Segmented
Object Manufacturing (SOM), a new RP process that can make large expanded polystyrene objects.
SOM objects can be used as patterns for Lost Foam Casting (LFC). This too is a hybrid process
making use of a new slicing concept that enables machining in thick layers. This research is funded
by GTRE Bangalore to the tune of Rs. 80 lakhs.

Introduction

Building 3D objects directly from their computer models without going through the tedious and time-consuming manufacturing steps of process planning
and tool manufacturing was merely science fiction until recently. A fairly recent and fascinating technology called Rapid Prototyping (RP) has made this a reality;
manufacture of complex 3D objects using RP is as easy and simple as printing a letter or a drawing or a picture. In fact, RP is also called 3D Printing or 3D
Faxing. CNC machines and robots are automatic only when their fool-proof paths are available whereas RP machines are truly and totally automatic as they
require only a valid 3D definition of the object geometry. Customer affluence, product obsolescence and global competition have increased product variety and
shortened product life and profit margins. In this scenario, organizational survival, leave alone their success, is solely through shorter time-to-market. RP,
launched in 1987, helps in shortening product development cycles.
RP, due to its linear time and cost behavior, is not suitable when more pieces are required.
But RP meets these needs of a few hundred or thousand pieces required for pre-production runs as well as limited-edition launches in conjunction with the
existing tools such as Silicon Rubber Molding (Vacuum Casting), Epoxy Tooling, Spray Metal Tooling, Kirksite Tooling, metal casting etc.. These are sometimes
referred as Rapid Tooling (RT). While RP compresses the product development cycle, RT shortens the product life cycle. In short, RP&T sharpens the competitive
edge of organizations to launch new products ahead of their competitors. Encouraged by the benefits of RP&T, these approaches are being explored for regular
production as well. This evolution of upgrading these fast technologies from prototypes to actual products is known as Rapid Manufacturing (RM). RP&M
technologies have revolutionized the way products are designed and manufactured today. As the products are diverse in material, geometric quality, quantity etc.,
the unique layered manufacturing approach of RP will not be adequate for RM. RM will require a number of multi-faceted and hybrid approaches. They are
classified into six major groups, viz., [i] Subtractive RM (CNC machining), [ii] Laminated Manufacturing, [iii] Powder-bed technologies, [iv] Deposition
technologies, [v] Hybrid RM ([ii] & [i], [iii] & [i], [iv] & [i]) and [vi] Indirect RM (Vacuum Casting, Epoxy Tooling, Spray Metal Tooling, Kirksite Tooling,
Rapid Casting etc.). Having a physical representation of the object quickly with the help of RP has far reaching implications for the designer because he can feel it
with more senses than just sound and vision based evaluation using CAD and CAE tools. Just like stone age, bronze age etc. which were milestones in
civilization, RP heralded the dawn of slice age for the manufacturing world. The RP&M market is growing rapidly day-by-day. Many design departments today
have dedicated RP machines, which have become as ubiquitous as photocopiers. RP&M has become an integral part of product development in many
organizations in India as well, thanks to the Governmental initiatives and other catalysts in academia. This course will attempt to give an overview of the various
RP&M technologies. After giving the necessary background in CAD modeling and Reverse Engineering, various popular RP processes will be discussed in detail.
These will include Fused Deposition Modeling (FDM), Selective Laser Sintering (SLS), Stereo-Lithography Apparatus (SLA), 3D Printing (3DP) and Laminated
Object Manufacturing (LOM). The second part will deal with the indirect processes which can duplicate the RP masters into multiple non-metallic pieces required
in pre-production runs and limited-editions. These include Vacuum Casting, Epoxy Tooling, Spray Metal Tooling and Kirksite Tooling. Thirdly the six groups of
RM processes will be dealt in great detail. Particular focus will be given to the processes for metallic objects including Rapid casting. Hybrid Layered
Manufacturing (HLM) and Segmented Object Manufacturing (SOM) are two interesting RM processes for metals at advanced stages of development at IIT
Bombay. These also will be presented and demonstrated. All the presentations will start with the detailed description of the process and then highlight on
important applications and case studies. Some of them will be accompanied by actual or video demos. Some modules will be presented by the domain experts in
aerospace, automotive and medicine.

Program Overview
Geometric Modeling
Reverse Engineering
Rapid Prototyping
Overview to Rapid
Manufacturing
Rapid Manufacturing of
Non-metallic Objects
Rapid Manufacturing of
Metallic Objects
Laminated
Manufacturing for
Metallic Objects
Powder-bed
Technologies for
Metallic Objects
Deposition Technologies
for Metallic Objects
Role of High Speed CNC
Machining in Rapid
Manufacturing
Design and
Manufacturing Using
Functionally Gradient
materials
Applications of Rapid
Manufacturing in
aerospace, automotive
and medicine