The module aims to provide a solid foundation in the theory and best practices of Rapid Prototyping and Manufacturing (RPM), with a focus on Additive Manufacturing (AM) - 3D Printing (3DP) and associated emerging and enabling technologies necessary for rapid development, innovation, and diversification of products and technology services, including Design for AM (DfAM), Design Thinking, Decision Making and Technology Selection in AM – 3DP. Comprehensive coverage of concepts and RPM principles, analytical and practical skills, technical and economic challenges, as well as emerging and enabling technologies, innovations and case studies will be introduced and discussed, to systematically enhance the knowledge, background and engineering practice in RPM in general and AM-3DP in particular. The module also focuses on developing the ability to critically evaluate how a modern organisation could strategically exploit AM – 3DP to innovate products and shorten the time for product design and development, taking into account the impacts of Smart Manufacturing and Industry 4.0 as well as Cloud Manufacturing and Supply Chain 4.0.

On successful completion of this module a student will be able to:
LO1 Demonstrate a systematic knowledge and understanding of concepts and principles, economic and technological aspects, emerging applications, current and future trends of RPM in general and AM-3DP in particular.
LO2 Demonstrate a systematic knowledge and understanding of AM-3DP technologies and process chain.
LO3 Apply a comprehensive knowledge of AM-3DP, associated emerging and enabling technologies and software solutions, for innovative development of AM-3DP applications.
LO4 Perform a critical evaluation and selection of AM-3DP technologies, associated emerging and enabling technologies and software solutions, for innovative development of products and services.

• Introduction to Rapid Prototyping and Manufacturing (RPM): Concepts and applications; economic and technological aspects of RPM in general and AM-3DP in particular
• A process chain of AM-3DP: Generation and optimisation of CAD models and design; preparation of machine acceptable file formats (STL, VRML, OBJ); Data preparation); Machine setup; Part removal; and Post-processing and finishing.
• AM-3DP technologies and processes: Overviews and classification; Liquid-based AM-3DP technologies and processes; Solid-based AM-3DP technologies and processes; Powder-based AM-3DP technologies and processes; Hybrid-manufacturing; Technical challenges and future development.
• Rapid Tooling and Rapid Manufacturing: Concepts, process chains and frameworks.
• Design for AM-3DP (DfAM): Design for X – concepts and definitions; DfAM methods and technologies: Topology Optimization, Design for Multiscale Structures (Lattice or Cellular Structures), Multi-material Design, Mass Customization, Personalised Design, Part Consolidation; Technical requirements and data preparation (Data processing, Data transfer, Support generation, Alignments - Build orientation, Nesting, Slicing).
• Associated emerging and enabling technologies and software solutions for RPM: CAD/CAM/CNC; Computer Aided Engineering (CAE); Reverse Engineering (RE); Computer-Aided Inspection (CAI) and Quality Control; Micro and Nano Manufacturing; Smart Manufacturing and Industry 4.0 (AI, Digital Twins, Big Data Analytics); Cloud Manufacturing and Supply Chain 4.0.
• Evaluation and selection of AM-3DP technologies, associated emerging and enabling technologies and software solutions, for innovative development of products and services: Decision-making models and technology selection, Selection criteria and requirements; Selection of AM-3DP technologies; Selection of AM-3DP software and data processing tools
• Literature reviews, case studies and/or lab sections, opportunities, emerging trends and future directions of AM-3DP as well as associated emerging and enabling technologies and software solutions.

Seminar:
When possible, guest lectures and seminars are provided by leading academics and professionals from industries as well as the visiting researchers and professors.
Lecture:
The lectures are supported with online-learning videos, comprehensive demonstrations, lecture notes and presentations. Additional guides and tutorials are available for students at the end of the main contents of a module. State of the art industrial applications and case studies are used to support presentations, tutorials and in-class activities, with an online access to digital learning materials, discussion forums, and training videos of software and tools.
Group Study:
The problem-based learning group projects and lab sections are designed for students to apply the theories into the practice, as well as to develop both practical and transferable skills.
Self-directed learning:
The blended learning and teaching mode is relevantly applied, with emerging digital learning and teaching tools and resources, such as online-learning videos, to support in-class activities, tutorials and self-learning.

Besides the scheduled learning and teaching activities and tutorials, the lecturers provide constructive comments and feedback, to support self-directed learning for students, via the use of the digital learning and teaching platforms, including Microsoft Teams Meeting, Panopto and Moodle.

Coursework - 100%
LO - 1-4.
Pass mark - 50%
1500 words.
An individual assignment, which is the Problem-based Learning (PBL) project, encompassing theoretical backgrounds and professional skills, with critical literature reviews and demonstrations of real-world case studies in Additive Manufacturing - 3D Printing.

Nature of FORMATIVE assessment/task supporting student learning:
1. Formative group project presentation: This aims to provide the constructive comments and feedback about the group project activities as well as to enhance the transferable and professional skills for students.