Hands-On Learning in Intelligent Manufacturing: Developing a Small-Scale Selective Laser Sintering (SLS) System

This project aims to enhance undergraduate education in intelligent manufacturing by integrating hands-on experience in Selective Laser Sintering (SLS) for polymers into the SYE curriculum. Currently, students have limited exposure to advanced manufacturing technologies, as existing courses focus primarily on theoretical concepts. For example, in SYE2010, only two lab sessions (three hours each) are arranged, providing minimal opportunities for students to explore emerging fabrication techniques. The department has invested in commercial polymer and metal 3D printers, but the lack of structured hands-on learning activities has prevented students from fully utilizing these technologies. To address this gap, this project will engage students in the design, assembly, and optimization of a homemade small-scale SLS system. Unlike traditional polymer 3D printing, which relies on filament extrusion, SLS is a powder-based additive manufacturing technique where a low-power CO₂ laser selectively sinters polymer powder layer by layer to create solid objects. By working in teams of three to five members, students will contribute to the development of different components of a small-scale SLS system and conduct experiments on laser sintering parameters such as power, scan speed, and layer thickness to study their impact on part quality and printing properties.To further enhance Virtual Teaching and Learning (VTL), a virtual SLS simulator will be developed, allowing students to design tool paths and slicing strategies for 3D models. This simulator will enable students to input laser parameters and visualize the predicted sintering pattern, bridging the gap between theoretical modeling and real-world experimental results. Additionally, a digital twin-based system will be introduced to help students evaluate printed part accuracy by comparing simulated vs. real printed parts by using a 3D scanner to scan the printed parts. A remote access component will allow students to upload part designs for the department’s polymer 3D printers and receive feedback on their printed parts. This feature will provide students with flexibility in conducting experiments, even if they cannot attend in-person lab sessions.The project’s success will be assessed through student surveys and evaluations of team project reports and presentations. The results will also be disseminated through teaching workshops and conferences, sharing best practices in advanced and intelligent manufacturing education. This initiative will not only enhance student learning but also lay the foundation for future courses in manufacturing. Outstanding students may have opportunities to continue research in optimizing laser sintering parameters and material selection, further strengthening the research-teaching nexus.