Advanced Manufacturing & Process Modelling Course | NPTEL | IISc Bangalore
Course Details
| Exam Registration | 219 |
|---|---|
| Course Status | Ongoing |
| Course Type | Elective |
| Language | English |
| Duration | 12 weeks |
| Categories | Metallurgy and Material science & Mining Engineering |
| Credit Points | 3 |
| Level | Undergraduate/Postgraduate |
| Start Date | 19 Jan 2026 |
| End Date | 10 Apr 2026 |
| Enrollment Ends | 02 Feb 2026 |
| Exam Registration Ends | 20 Feb 2026 |
| Exam Date | 24 Apr 2026 IST |
| NCrF Level | 4.5 — 8.0 |
Master the Future of Manufacturing: A Deep Dive into Process Modelling
The manufacturing landscape is undergoing a radical transformation, driven by digitalization and the need for first-time-right production. At the heart of this revolution lies Process Modelling – the powerful capability to simulate, analyze, and optimize manufacturing processes before a single part is made. If you're an engineering student or professional looking to build a future-proof skill set, the NPTEL course "Advanced Manufacturing and Process Modelling" is your gateway.
Led by Prof. Prosenjit Das from the prestigious Indian Institute of Science (IISc) Bangalore, this comprehensive 12-week course bridges the gap between traditional manufacturing knowledge and cutting-edge computational techniques.
Meet Your Instructor: Prof. Prosenjit Das
Learning from an expert with both deep academic research and significant industrial translation experience is invaluable. Prof. Prosenjit Das brings exactly that to the table. Currently an Assistant Professor in the Department of Materials Engineering at IISc Bangalore, he has a distinguished background, including a 12-year tenure as a Principal Scientist at CSIR-CMERI.
His expertise is vast, encompassing Casting & Solidification, Bio-inspired Manufacturing, Metallurgical Process Modelling, and Fracture Mechanics. With over 65 SCI journal publications, 4 Indian patents with technology transfer potential, and guidance for numerous PhD and MTech students, Prof. Das is a leader in the field. His ability to translate basic research into viable industrial processes, backed by approximately ₹8 crores in research funding, ensures the course content is both theoretically sound and practically relevant.
Who Should Enroll in This Course?
This course is meticulously designed for:
- Undergraduate and Postgraduate students in Metallurgy, Materials Science, Mechanical Engineering, Manufacturing Engineering, and Mining Engineering.
- Research scholars focusing on manufacturing process optimization.
- Industry professionals in R&D, process planning, and simulation roles seeking to upskill.
Prerequisites & Industry Relevance
To get the most out of this course, a foundation in Elementary Mathematics and Mechanics is recommended. Familiarity with basic manufacturing processes through courses like Manufacturing Process Technology (Parts I & II) is advantageous.
The course boasts strong industry support, with relevance to major players like Tata Steel, Ashok Leyland, L&T, Mahindra & Mahindra, HAL, BHEL, and automotive giants like Maruti Suzuki and Bajaj Auto. It also aligns with projects funded by agencies like CSIR, DST, ISRO, and DRDO, highlighting its importance in both commercial and strategic sectors.
Detailed 12-Week Course Layout
The course is structured to provide a logical progression from fundamentals to advanced applications across key manufacturing domains.
| Week | Core Topics Covered |
|---|---|
| Week 1-2 | Foundations: Introduction to manufacturing science, numerical methods (FDM, FVM, FEM, BEM), and casting process fundamentals including pattern, gating, and riser design. |
| Week 3-4 | Advanced Casting Modelling: Die-filling analysis, solidification physics, transport phenomena, and multiscale modelling using Finite Volume and Phase Field methods. |
| Week 5-6 | Welding Process Modelling: Weld metallurgy & mechanics, analytical/BEM solutions for heat conduction, multiphase flow modelling of melt pools, and thermo-mechanical modelling of residual stress. |
| Week 7-8 | Powder Metallurgy Simulation: Mechanics of sintering, modelling of processes like Hot Isostatic Pressing and Injection Moulding, using continuum FE models and Molecular Dynamics. |
| Week 9 | Additive Manufacturing (3D Printing): Modelling of melting/solidification, mass-transfer, and microstructure evolution in multi-layer, multi-track processes. |
| Week 10-11 | Metal Forming Analysis: Slab and slip-line analysis, Forming Limit Diagrams (FLDs), and comprehensive Finite Element Analysis (FEA) of forging, rolling, and drawing. |
| Week 12 | Machining Modelling: Analytical and FE modelling of orthogonal machining, chip formation, and prediction of cutting forces for alloys and composites. |
Key Learning Outcomes
By the end of this course, you will be able to:
- Understand the core physics behind major manufacturing processes.
- Select and apply appropriate numerical methods (FEA, FVM, BEM) for process simulation.
- Develop and interpret models for casting solidification, welding residual stress, sintering densification, and metal forming deformation.
- Gain insights into microstructure evolution and defect generation through modelling.
- Use process models as a tool for optimization, control, and improving product quality.
Essential Reference Books
The course is complemented by standard textbooks to strengthen your understanding:
- Rao, P.N., Manufacturing Technology Vol. 1 & 2
- Ghosh & Malik, Manufacturing Science
- Khanna, O.P., Foundry Technology
- Dieter, G.E., Mechanical Metallurgy
Advanced Manufacturing and Process Modelling is more than just a course; it's an investment in mastering the digital tools that define modern manufacturing. Under the expert guidance of Prof. Prosenjit Das, you will gain the skills to not just understand processes, but to predict, optimize, and innovate them. Enroll today and take the first step towards becoming a leader in the smart manufacturing revolution.
Enroll Now →