Additive Manufacturing Course

Lesson 1 • History and Evolution of AM

Traces AM from 1980s stereolithography to modern multi-material systems. Contextualises technological milestones driving current industrial adoption.

Lesson 2 • AM vs. Conventional Manufacturing

Compares geometric freedom, lead time, material waste, and tooling costs between AM and subtractive or formative processes. Guides technology selection logic.

Lesson 3 • Core AM Terminology and Concepts

Defines layer-by-layer fabrication, build envelope, resolution, and support structures. Provides shared vocabulary for all subsequent technical chapters.

Lesson 4 • Industrial Applications Overview

Surveys AM deployment across aerospace, medical, automotive, and consumer sectors. Connects process selection to real-world performance requirements.

Lesson 1 • Ceramics and Composites in AM

Introduces ceramic slurries, filled polymers, and continuous fiber composites. Highlights sintering requirements and fiber-matrix interface considerations.

Lesson 2 • Material Selection Frameworks

Applies structured decision tools to match material to process, application environment, and cost constraints. Integrates biocompatibility and regulatory considerations.

Lesson 3 • Polymer Feedstocks for AM

Covers thermoplastics, thermosets, and elastomers used in extrusion and photopolymer processes. Links molecular structure to printability and part performance.

Lesson 4 • Metal Powders and Wires

Examines powder morphology, particle size distribution, and flowability for PBF and DED. Addresses alloy families and their AM-specific processing challenges.

Lesson 1 • Tolerances, Fits, and Surface Finish

Establishes achievable dimensional tolerances and surface roughness by process. Guides designers in specifying post-processing requirements for functional interfaces.

Lesson 2 • Support Structure Strategy

Determines overhang angles, self-supporting geometries, and support minimisation through orientation and design changes. Reduces post-processing time and material waste.

Lesson 3 • Design Validation and Iteration

Uses simulation, test builds, and structured review to validate DfAM decisions before full production. Closes the design-build-test feedback loop.

Lesson 4 • Topology Optimisation Techniques

Applies load-path-based material distribution algorithms to reduce mass while meeting stiffness targets. Connects optimisation outputs to printable geometries.

Lesson 5 • Lattice and Cellular Structures

Designs strut-based, surface-based, and stochastic lattices for lightweight and energy-absorbing applications. Addresses printability limits and node stress concentrations.

Lesson 1 • Machine Communication and Job Setup

Covers G-code, proprietary machine formats, and pre-build checklists. Ensures correct machine state before initiating a build to prevent costly failures.

Lesson 2 • Mesh Repair and Optimisation

Identifies and fixes non-manifold edges, holes, inverted normals, and intersecting shells. Ensures watertight geometry required for slicing and build success.

Lesson 3 • Build Plate Layout and Nesting

Optimises part placement for thermal uniformity, support minimisation, and machine utilisation. Addresses nesting strategies for polymer and metal systems.

Lesson 4 • Slicing Software and Parameters

Configures layer height, infill, wall count, and print speed in slicing software. Links parameter choices to part quality, strength, and build time outcomes.

Lesson 1 • Vat Photopolymerisation Processes

Explains SLA, DLP, and MSLA exposure mechanics, resin handling, and cure depth control. Connects exposure parameters to dimensional accuracy and surface quality.

Lesson 2 • Selective Laser Sintering for Polymers

Details powder bed preparation, laser energy density, and part cake management for SLS. Addresses powder refresh ratios and mechanical property consistency.

Lesson 3 • Material Jetting and PolyJet

Covers multi-material jetting, support material removal, and achievable accuracy for PolyJet systems. Highlights applications in colour prototyping and overmould simulation.

Lesson 4 • Fused Filament Fabrication Operations

Covers extruder mechanics, bed adhesion, temperature profiles, and retraction settings for FFF. Addresses common defects: stringing, warping, layer delamination.

Lesson 1 • Electron Beam Powder Bed Fusion

Explains EB-PBF elevated temperature processing, sintered powder cake, and vacuum environment advantages. Addresses microstructure differences vs. laser-based PBF.

Lesson 2 • Directed Energy Deposition Processes

Covers laser and arc-based DED for repair, cladding, and large-format fabrication. Addresses dilution, heat-affected zones, and multi-axis deposition strategies.

Lesson 3 • Laser Powder Bed Fusion Operations

Covers laser power, scan speed, hatch spacing, and layer thickness interactions in PBF-LB. Links parameter sets to density, microstructure, and residual stress outcomes.

Lesson 4 • Metallurgical Quality and Inspection

Applies microstructural analysis, CT scanning, and mechanical testing to verify metal AM part integrity. Connects inspection results to process parameter adjustments.

Lesson 1 • AM Quality Management Frameworks

Introduces quality management system requirements adapted for AM, including process qualification, traceability, and document control. Connects to aerospace and medical standards.

Lesson 2 • In-Situ Process Monitoring

Covers melt pool monitoring, thermal imaging, and layer-wise optical inspection systems. Enables real-time defect detection without destructive testing.

Lesson 3 • Statistical Process Control in AM

Implements control charts, Cpk analysis, and DOE to monitor and improve AM process stability. Identifies critical-to-quality parameters for ongoing control.

Lesson 4 • Dimensional Metrology for AM Parts

Applies CMM, structured light scanning, and CT metrology to complex AM geometries. Addresses GD&T interpretation and first-article inspection protocols.

Lesson 1 • Surface Finishing Methods

Covers abrasive blasting, tumbling, electropolishing, and chemical smoothing to reduce Ra and improve fatigue life. Matches method to geometry and material.

Lesson 2 • Thermal Post-Processing for Metals

Explains stress relief, HIP, annealing, and solution aging heat treatments for AM metals. Links thermal cycles to microstructure homogenisation and fatigue improvement.

Lesson 3 • Machining and Finishing Operations

Applies CNC machining, grinding, and EDM to achieve tight tolerances on AM near-net-shape parts. Addresses fixture design for complex AM geometries.

Lesson 4 • Coatings and Functional Treatments

Applies PVD, anodising, painting, and infiltration to enhance corrosion resistance, wear, and aesthetics. Addresses coating adhesion on AM surface textures.