Additive Manufacturing
Level: Graduate Course
Instructor: Dr. Adeel Ikram
Offered in Semesters: Spring 2023, Spring 2024, and Spring 2025
Course Code: TCW701280
Course Learning Outcomes
By the end of this course, graduate students will be able to:
- Explain the fundamentals and significance of Additive Manufacturing (AM), including its historical development, benefits, and applications across industries such as medical, aerospace, and automotive.
- Differentiate between major AM processes, such as binder jetting, directed energy deposition, powder bed fusion, and others, by describing their working principles, materials used, advantages, and limitations.
- Analyze the materials used in AM and understand the evolution of microstructure, properties, and defects in AM-manufactured parts.
- Apply design principles specific to AM, including considerations for support structures, build orientation, and geometric constraints unique to additive manufacturing.
- Evaluate post-processing techniques and quality assurance methods to improve part performance and ensure process reliability, with a focus on laser powder bed fusion.
- Assess the sustainability and market potential of AM, including its environmental impact, lifecycle assessment, and emerging trends in hybrid and circular manufacturing approaches.
Course Overview
The course will start by introducing the fundamentals of Additive Manufacturing (AM), also known as 3D printing, and its transformative role in modern manufacturing. We will discuss the historical evolution of AM, its current and projected importance to the U.S. manufacturing sector, and its growing applications across diverse fields such as aerospace, automotive, medical, construction, energy, defense, food, electronics, and fashion. The vision and value of AM will be outlined, highlighting how it enables customized, lightweight, and complex structures that are otherwise difficult or impossible to manufacture with traditional techniques.
Students will be introduced to the vocabulary and core steps of the AM process, ranging from single-step to multi-step approaches. Each major AM process—including binder jetting, directed energy deposition, powder bed fusion, vat photopolymerization, material extrusion, material jetting, and sheet lamination—will be studied in depth. For each process, we will cover the working principles, equipment, materials, benefits, drawbacks, and real-world industrial applications, using case studies from leading companies such as Stratasys, Markforged, XJet, Desktop Metal, and ExOne.
Beyond process understanding, the course will delve into the science of AM materials, including polymers, metals, ceramics, and bio-inks. We will explore how microstructure evolves during AM and its effect on mechanical properties and performance. This includes studying thermal gradients, defects, residual stresses, and strategies for optimization and control.
Post-processing techniques—such as stress relief, hot isostatic pressing, surface finishing, and support removal—will be introduced, along with quality assurance approaches including in-situ monitoring and optical tomography. The course will emphasize the importance of design for additive manufacturing (DfAM), focusing on design freedom, build orientation, support structures, thermal considerations, and part consolidation.
In the final weeks, we will assess the sustainability of AM technologies through life cycle assessment, hybrid and circular manufacturing strategies, and material efficiency. The course will conclude by evaluating the future prospects, cost considerations, and market trends of AM across industries.
This course is ideal for graduate students from mechanical, industrial, materials, biomedical, and manufacturing engineering backgrounds. No prior AM experience is required. However, basic knowledge in manufacturing processes and materials science will be beneficial.
Course Topics
- Introduction to additive manufacturing and 3D printing technologies
• History, vision, and significance of AM in modern manufacturing
• Applications of AM in medical, aerospace, automotive, and other industries
• AM vocabulary and process stages (single-step and multi-step)
• Overview of major AM processes (binder jetting, DED, PBF, etc.)
• Directed energy deposition (DED) – principles, wire and powder-based systems
• Powder bed fusion (PBF) – laser and electron beam-based processes
• Binder jetting (BJT) – polymers and metals, sintering and post-processing
• Material jetting (MJT) – droplet formation, applications, and challenges
• Material extrusion (MEX) – fused deposition modeling, metals, and bioextrusion
• Vat photopolymerization (VPP) – stereolithography and two-photon polymerization
• Sheet lamination (SL) – bonding techniques and applications
• Design for additive manufacturing (DfAM) – principles and optimization
• Materials for AM – polymers, metals, ceramics, and bio-materials
• Properties of AM materials and common defects
• Post-processing techniques and quality assurance in AM
• Sustainability and life cycle analysis of AM technologies
• Market trends, economic feasibility, and future prospects of AM
Delivery Method
Lectures will be delivered using PowerPoint presentations
Reference Books
Ian Gibson, David Rosen, and Brent Stucker, Additive Manufacturing Technologies: 3D Printing, Rapid Prototyping, and Direct Digital Manufacturing, 2nd Edition, Springer, 2015.
Stefanie Brückner, Mirko Meboldt, Additive Manufacturing: Design, Methods, and Processes, Springer, 2023.
Assessment and Evaluation
Examination Weightage:
- Midterm Exam: 30%
- Sessional Work (Assignments/Projects/ Presentations): 20%
- Final Exam: 50%
In the written examinations, students will demonstrate their understanding of additive manufacturing principles, processes, materials, and related physical phenomena by responding to conceptual and applied questions.
Computational Fluid Dynamics (CFD)
Level: Graduate Course
Instructor: Dr. Adeel Ikram
Offered in Semester: Fall 2023
Course Code: TCW701300
Course Learning Outcomes
By the end of this course, students will be able to:
- Understand the fundamental principles of CFD and its historical development.
- Explain key concepts in fluid dynamics, solid mechanics, and continuum mechanics.
- Derive and interpret conservation laws (mass, momentum, energy) using CFD tools.
- Differentiate between Lagrangian and Eulerian frameworks in fluid motion.
- Analyze stress, strain rate, and vorticity fields using tensor representations.
- Utilize COMSOL Multiphysics to set up and solve real-world CFD problems.
- Perform simulations for fluid flow and heat transfer using appropriate boundary conditions
- Evaluate CFD results to support engineering design and research in fluid mechanics.
Course Overview
This course introduces the principles and applications of Computational Fluid Dynamics (CFD), focusing on fluid flow analysis through numerical methods and simulations. The course begins with fundamental fluid mechanics, finite element methods (FEM), and the mathematical background of partial differential equations (PDEs). Students will then explore key computational techniques and continuum mechanics concepts, such as Lagrangian and Eulerian approaches, control volumes, motion and deformation, stress tensors, and flow field analysis. Special attention will be given to the derivation of Navier-Stokes equations and conservation laws using CFD principles. The latter part of the course is focused on practical simulation using COMSOL Multiphysics software, involving case studies including laminar flow, heat transfer, capillary action, and microfluidic inkjet systems.
Course Topics
- Introduction to CFD and finite element methods (FEM)
• Mechanics and computational mechanics fundamentals
• Solid and structural mechanics in CFD context
• FEM modeling and solution techniques
• Fluid states, forces, and continuum mechanics
• Lagrangian and Eulerian approaches
• Fluid motion, deformation, and strain rates
• Tensor quantities, stress tensors, and vorticity
• Scalar and vector fields in fluid dynamics
• Conservation of mass, momentum, and energy
• Navier–Stokes equations and flow equations in CFD
• Heat transfer and boundary condition modeling
• Introduction to COMSOL Multiphysics
• CFD simulation of laminar flow and heat transfer
• Advanced CFD case studies using COMSOL
• Capillary and inkjet simulations with Level Set and Phase Field methods
Delivery Method
Lectures will be supported by dynamic visualizations, PowerPoint slides, and live demonstrations. Simulation exercises will be conducted using COMSOL Multiphysics software in lab environments, with hands-on guidance. Additional materials such as tutorials, solver walkthroughs, and example projects will be provided to strengthen independent learning.
Reference Books
Jiyuan Tu, Guan Heng Yeoh, Chaoqun Liu, Computational Fluid Dynamics: A Practical Approach, 3rd Edition, Butterworth-Heinemann, 2018.
Anders Logg, Kent-Andre Mardal, Garth Wells, Automated Solution of Differential Equations by the Finite Element Method: The FEniCS Book, Springer, 2012 (for FEM fundamentals).
Assessment and Evaluation
Examination Weightage:
- Midterm Exam: 30%
- Sessional Work (Assignments, Presentations, Simulation Reports): 20%
- Final Exam: 50%
In written assessments, students will demonstrate their knowledge of CFD theory and fluid mechanics principles. Through practical assignments, they will showcase their ability to conduct CFD simulations, interpret results, and apply findings to engineering problems.
Engineering Materials
Level: Undergraduate Course
Instructor: Dr. Adeel Ikram
Offered in Semesters: Spring 2023
Course Code: TAS604150
Course Learning Outcomes
By the end of this course, students will be able to:
- Identify and classify engineering materials based on their composition, structure, and application.
- Analyze the relationship between the atomic structure of materials and their properties.
- Understand crystal structures, defects, and diffusion mechanisms in solid materials.
- Interpret stress-strain behavior and mechanical properties of various material types.
- Read and apply binary phase diagrams, especially the iron–carbon system, for predicting phase transformations.
- Describe the processes and effects of heat treatment on plain carbon steels.
- Discuss the properties and applications of different classes of alloys, polymers, ceramics, and composites.
- Evaluate the suitability of engineering materials for specific industrial applications.
Course Overview
This course provides a comprehensive foundation in materials science and engineering, exploring the fundamental types, structures, properties, and applications of engineering materials. It covers metals, polymers, ceramics, composites, and advanced materials including electronic, smart, and nanomaterials. The course will introduce crystallography, mechanical behavior, phase transformations, and thermal treatments. Through this course, students will gain the necessary understanding to select and manipulate materials for various engineering applications.
Course Topics
- Introduction to materials science and classification of materials
• Crystal and amorphous structures
• Atomic packing and crystallographic directions/planes
• Solidification and grain structure formation in metals
• Crystalline imperfections and defect types
• Atomic diffusion mechanisms
• Mechanical behavior of materials and stress-strain relationships
• Phase diagrams and equilibrium phases
• Iron–Iron-Carbide phase diagram
• Heat treatment of steels and transformation diagrams
• Non-ferrous alloys: Aluminum, Copper, Stainless Steel, Nickel
• Polymeric materials and ceramic processing
• Composite materials and their classifications
Delivery Method
Lectures and exercises will be delivered in-person using interactive presentations and visual aids to support conceptual learning. Supplementary videos, microstructure images, and physical samples may be included for enhanced engagement. Students will also receive guidance on using software tools for phase diagram interpretation and mechanical property prediction.
Reference Books
William Smith, Javad Hashemi, Foundations of Materials Science and Engineering, 6th Edition, McGraw Hill Education, 2019.
Assessment and Evaluation
Examination Weightage:
- Midterm Exam: 30%
- Sessional Work (Assignments/ Presentations/Case Studies): 20%
- Final Exam: 50%
In the written exams, students will demonstrate their understanding of material science concepts, structures, properties, and processing techniques by solving theoretical and application-based problems.
Manufacturing Processes
Level: Undergraduate Course
Instructor: Dr. Adeel Ikram
Offered in Semesters: Spring 2024
Course Code: TAS604670
Course Learning Outcomes
By the end of this course, students will be able to:
- Understand the role and scope of manufacturing in engineering and industry.
- Identify different materials used in manufacturing and describe their behavior under stress, heat, and mechanical processes.
- Explain and compare traditional manufacturing techniques such as casting, forming, machining, and welding.
- Describe polymer processing methods including injection molding, extrusion, and blow molding.
- Understand the fundamentals of powder metallurgy and sintering techniques.
- Evaluate advanced manufacturing processes including EDM, waterjet cutting, and additive manufacturing.
- Analyze manufacturing process selection based on product requirements and material properties.
- Apply knowledge of production systems, tooling, and process parameters in practical scenarios.
Course Overview
This course provides an in-depth introduction to manufacturing processes used across industries to convert raw materials into finished products. It begins with the fundamentals of manufacturing systems and material properties, then advances through various traditional and modern manufacturing techniques. Students will explore forming, casting, machining, welding, polymer processing, powder metallurgy, and additive manufacturing processes. The course also covers key aspects of material behavior under different conditions, including stress-strain relationships, temperature effects, and material selection for specific manufacturing applications. Special attention will be given to understanding the operating principles, advantages, limitations, and applications of each manufacturing process.
Course Topics
- Introduction to manufacturing and production systems
• Stress-strain relationships and mechanical properties
• Materials in manufacturing: metals, ceramics, polymers, composites
• Casting processes: sand casting, mold types, solidification
• Glassworking, heat treatment, and product design in casting
• Polymer processing: extrusion, injection molding, blow molding, thermoforming
• Powder metallurgy: powder production and sintering
• Metal forming processes: rolling, forging, extrusion
• Sheet metal operations: cutting, bending, drawing
• Machining processes: turning, drilling, milling, grinding
• Non-traditional machining: EDM, Wire-EDM, water jet cutting
• Welding processes: arc welding, laser welding, solid-state welding
• Additive manufacturing technologies: DED, PBF, BJT, MJT, MEX, VPP, SL
Delivery Method
Lectures will be supported by engaging presentations, multimedia demonstrations, and process simulations. Practical sessions will involve component analysis, virtual labs, and manufacturing case studies. Assignments and assessments will emphasize real-world problem-solving and decision-making in manufacturing environments.
Reference Books
Mikell P. Groover, Fundamentals of Modern Manufacturing: Materials, Processes, and Systems, 7th Edition, Wiley, 2020.
Assessment and Evaluation
Examination Weightage:
- Midterm Exam: 30%
- Sessional Work (Assignments, Case Studies, Quizzes): 20%
- Final Exam: 50%
The exams will assess the students’ understanding of core manufacturing processes, material behavior, and process selection. Sessional work will evaluate their ability to apply concepts to industrially relevant tasks and scenarios.
Finite Element Method
Level: Undergraduate Course
Instructor: Dr. Adeel Ikram
Offered in Semesters: Fall 2023 and Fall 2024
Course Code: TAS604660
Course Learning Outcomes
By the end of the course, students will be able to:
- Understand the theoretical foundations and mathematical formulation of FEM.
- Apply variational principles and weighted residual methods in finite element formulations.
- Develop and solve finite element models for 1D, 2D, and 3D engineering problems.
- Use interpolation functions, numerical integration, and mesh generation effectively.
- Analyze structures including trusses, beams, frames, plates, and shells using FEM.
- Evaluate convergence, accuracy, and stability of finite element solutions.
- Apply FEM to thermal, structural, electromagnetic, and fluid interaction problems.
- Use COMSOL Multiphysics software for modeling and simulation of multidisciplinary problems.
Course Overview
This course introduces the Finite Element Method (FEM), a powerful numerical technique used for solving complex engineering problems involving solid mechanics, structural analysis, heat transfer, fluid flow, and electromagnetics. The course covers both theoretical foundations and practical applications of FEM, including formulation methods, numerical integration, error estimation, and modeling techniques. Students will also gain hands-on experience using COMSOL Multiphysics, a commercial FEM software tool, to simulate and analyze real-world engineering problems across multiple domains.
Course Topics
- Introduction to FEA, elasticity, stiffness method, potential energy
• Formulation techniques: virtual work, Galerkin, displacement method
• Variational principles, differential equations, boundary conditions
• Interpolation techniques, shape functions, Lagrange polynomials
• 1D and 2D element analysis, mesh generation, Gaussian quadrature
• Iso-parametric elements, triangular and rectangular elements
• Truss, beam, and frame analysis, static condensation
• FEM for 2D/3D solids, axisymmetric elements, stress computation
• FEM for plates, shells, skew plates, finite strip method
• FEM in stability, dynamic analysis, and fluid mechanics
• Error estimation, convergence, and solution verification
• FEM applications to heat transfer, solid mechanics, fluid mechanics
• Introduction and practical usage of COMSOL Multiphysics
• COMSOL applications in heat transfer, structural analysis, and CFD
• Multiphysics simulations: fluid-structure interaction and beyond
Delivery Method
The course will be delivered through a combination of interactive lectures, software demonstrations, hands-on modeling labs, and group projects. Multimedia tools and FEM software tutorials will be used to strengthen understanding of complex concepts and provide simulation experience.
Reference Books
Daryl L. Logan, A First Course in the Finite Element Method, 5th Edition, Cengage Learning, 2012.
Assessment and Evaluation
Examination Weightage:
- Midterm Exam: 30%
- Sessional Work (Assignments, Simulations, Presentations): 20%
- Final Exam: 50%
The assessments will evaluate the students’ theoretical understanding, ability to formulate FEM models, and proficiency in using FEM software for engineering analysis.