AM Materials (Metals & Polymers)
This course provides an overview of AM metal and polymer materials available using direct metal laser melting (DMLM) and fused deposition modeling (FDM™) processes respectively. The purpose of this course is to educate current and future users on AM materials and their characteristics, and give foundational guidance in material selection for part fabrication. Additionally, material handling and storage guidelines for each process are discussed.
Cold Spray Materials
This course provides an overview of the materials available for use in Cold Spray repairs. The purpose of this course is to educate current and future users on the material options available, existing purchase specifications, and guidelines for proper receiving, storage, and handling of powders.
Design for Cold Spray
This course targets engineers interested in learning the special considerations needed when designing repairs using Cold Spray. This presentation will cover design rules and best practices including, but not limited to, material selection, surface preparation, and guidelines to achieve the best adhesion for different repair geometries.
Design for AM (Metals)
This course targets engineers interested in learning the special considerations needed when designing metallic parts using Direct Metal Laser Melting (DMLM). In this presentation AM part suitability, design rules, and best practices including, but not limited to, support strategies, part placement on the build plate, and surface finish considerations will be discussed.
Design for AM (Polymers)
This course targets AM engineers focused on designing parts for polymer additive manufacturing using the FDM™ process. This course will cover design rules and best practices including, but not limited to, support angles, thin wall features, lettering and printed detail limitations, and clearances.
AF AM Policy (Guidance)
This course covers the policies and guidance documents that are in development or that have been released within the Air Force with respect to Additive Manufacturing and Cold Spray. The purpose of this course is to familiarize attendees with the intent of the documents and how AM & CS will be integrated into current AF systems. Additional topics will include equipment acquisition, strategic goals, and the specific roles of AFLCMC and the MTO in implementation of these exciting technologies.
AM Facility Requirements (Guidance)
This course provides information regarding Additive Manufacturing facility requirements. These guidelines are based on equipment installation and operational needs in addition to material storage and safety regulations. Furthermore, this course outlines the environmental and safety solutions that are necessary to protect users and meet general regulations.
Fundamentals of AM & Cold Spray
This course is an introductory presentation to both Additive Manufacturing and Cold Spray. Each process, their common uses, advantages and disadvantages of each technology, and the path to overcome the challenges each technology is facing will be covered. Finally, the Air Force’s vision and goals will be discussed for both technologies.
Support Structure Considerations (Metals & Polymers) for DMLM and FDM™
This course provides information regarding support structure design and considerations for DMLM (metal) process. This information includes types of support and their advantages, support removal, and key considerations to effectively support the part during the print process while minimizing the amount of support needed.
Post Processing (Metals)
This course discusses the post processing steps to complete fabrication of a metal part produced using DMLM. Best practices for post processing will be discussed including, but not limited to, heat treatment, support removal, machining features, and surface finish enhancement processes.
Support Structure and Post Processing (Polymers)
This course discusses support structure considerations for polymers using material extrusion technology along with the possible post processing steps to complete fabrication of a polymer FDM™ part. Support removal, including both break away and dissolvable supports, will be discussed in depth. Additionally, best practices for machining features and surface finish enhancement options will be discussed.
AM Case Studies
These courses provide an in-depth look at the steps taken to produce and validate AM parts from concept design to installation for Air Force sustainment. For each example, the challenges faced throughout the process will be discussed, along with the solution for each challenge and the lessons learned. AM case studies for metal and polymer parts will be held separately, and best practices will be reviewed for each type of part and each process.
Cold Spray Case Studies
This course provides an in-depth look at the steps taken to repair parts using cold spray technology for Air Force sustainment. The repair will be discussed from concept to implementation and finally qualifications. Challenges and lessons learned for each example will also be presented.
Types of AM Processes
This course provides an overview of the wide variety of Additive Manufacturing technologies available in the market in addition to DMLM and FDM™. The advantages and disadvantages of each of these technologies will be discussed.
SolidWorks Refresher Training
This course is a hands-on class suitable for individuals with prior SolidWorks experience who do not use the software on a daily basis and need a refresher course. The most commonly used SolidWorks tools for part creation, assembly generation, and 2D drawing construction will be reviewed using examples. This accelerated course lasts less than 2 hours and will be limited to 25 applicants. Each person registered for this course will be assigned a workstation with a full SolidWorks license. A separate introductory course will be offered for individuals with no 3D CAD experience.
Basic SolidWorks Training
This course is an introductory hands-on course to SolidWorks for individuals with no previous SolidWorks or CAD experience. In this course, the basics of part creation will be covered using the most common SolidWorks tools. Additionally, the basic steps to creating 2D drawings from the 3D models generated in SolidWorks will be demonstrated. This course lasts 4 hours and will be limited to 25 applicants, each of whom will be assigned their own workstation with a full SolidWorks license. A separate course will be offered for individuals with SolidWorks experience that simply need a brief refresher to get back to full effectiveness.
Scanning and Modeling with DesignX
This course provides hands-on training using the FARO Arm scanner and DesignX software for engineers and technicians. The purpose of this course is to cover the preliminary steps necessary to 3D scan a part using a FARO Arm scanner, and convert the collected point cloud data into a 3D model.
This process includes collecting the point cloud data from the scanner, and processing the collected data using DesignX software. Data processing using DesignX includes the steps necessary to convert the point cloud into a mesh, combining multiple meshes that were collected from the different sides of the part, and creating a surface model that could be directly converted into a .stl file and printed on a 3D printer if no other modifications are necessary.
Additionally, this course will cover the necessary steps to convert the surface model into a solid model that could be opened and modified in SolidWorks when changes and modifications are needed on the part.
Build File Preparation and Support Generation (Metals)
This course provides an overview of the steps required to prepare a 3D CAD model for printing on an EOS M290 DMLM machine. Attendees will be introduced to the production level software to generate support structure, orient part on the build plate, slice, setup print parameters, and generate G-code. This hands-on course lasts less than 2 hours and will be limited to 25 applicants, each of whom will be able to follow along with the instructor on their own workstation.
Polymer - Support structure & print file preparations with Insight
This course provides hands-on training on the Insight software for engineers and technicians. The purpose of this course is to cover the steps necessary to import an .stl file into Insight and prepare the file for printing on Fortus polymer printers. These steps include adjusting print orientation, generating support structure, selecting and changing printer and print material, changing infill, slicing the file, and exporting the print file.
Additionally, the necessary steps for adding auxiliary support walls will be covered for parts and geometries that require additional support during the build. Finally, this course covers the necessary steps for setting up a build plate with multiple print files created in Insight using Control Center.
Advanced polymer print file preparations with Insight
This course provides hands-on training of Insight software for AM engineers and technicians. The purpose of this course is to introduce more advanced tools that could be used within the Insight software platform to perform manual adjustments and changes to the polymer build file. These changes include necessary steps to changing infill patterns in different sections of the part, creating infill patterns that would provide an escape path for fluids or air in parts, changing the tool path, and adjustments to improve hole printing.
Tips & Tricks - Hands on FDM printing with Fortus 900 (Polymers) for Novice users - Parts 1 & 2
This course is targeting users new to FDM printing with Stratasys Fortus 900mc polymer printer. The purpose of this course is to provide hands-on training including, but not limited to, safety, material changes, nozzle changes, part loading, printing, unloading, support removal, and general maintenance. Perspective operators that take this course are expected to complete an Online Polymer Operator Course prior to attending which will provide familiarization with Additive Manufacturing, the FDM™ process, and the user interface of the Stratasys Fortus 900mc to enable maximum effectiveness in this hands-on course.
Registration is limited to 4 operators for each of 4 sessions to ensure effective delivery of the course content and adequate individual interaction with the equipment. This course is provided in 2 parts and both part 1 and part 2 of the sequence must be completed.
Tips & Tricks on FDM printing with Fortus Polymers printers for current users
This course is targeted at current users of the Stratasys Fortus printers. The content is to focus on tips, tricks, and best practices using examples and lessons learned. Additionally, Fortus 900mc high performance package requirements and capabilities will be discussed and demonstrated.
Registration is limited to 4 technicians for each of six sessions to ensure effective delivery of the course content and adequate individual interaction with the equipment.
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