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Metal Additive Manufacturing – Fundamentals and Process Technology
Last Updated: 2026-06-03 00:14:17
Abstract
This lecture gives an introduction to the fundamentals and process technology of additive manufacturing processes with a focus on metals. The principles and technologies of laser powder bed fusion, directed energy deposition as well as sintering processes will be introduced.
Objective
The students will learn - the physics of the most important metal additive manufacturing processes including the interaction of energy sources (laser, electron beams, arc/plasma) and metals, the phenomena occurring during melting and solidification, the generation of stresses and defects - the capabilities and limits of these processes - the digital aspects of the process chains including preparation of geometries, slicing, hatching etc. including assessment of printability of a design - working principles of machines, equipment and technology - basics of sensors and process control - post processing steps and interaction with AM material - future trends in metal AM
Content
Unit 1: Introduction to the AM workflow at the example of FDM Unit 2: Overview of Metal AM processes Unit 3: Making parts from weld beads Unit 4: Heat Flow, Melt Pool Dynamics, and Heat Sources Unit 5: Residual Stress and Distortion Unit 6: Laser Powder Bed Fusion - Build Layout Unit 7: Laser Powder Bed Fusion - Process Optimization and Design of Experiments Unit 8: Cost Modeling Unit 9: Lightweight Design using AM Unit 10: Powder Fabrication and Characterization Unit 11: Directed Energy Deposition Unit 12: Post-processing Unit 13: Materials for Metal AM Unit 14: Binder Jetting and sinter-based AM Unit 15: Simulation of AM Processes Unit 16: Process monitoring and closed-loop control of AM processes
Resources
Lecture Notes
The lecture slides and lecture notes will be distributed via moodle.
Literature
A list of references be given in the lecture.
General Information
- Language
- English
- Levels
- BSC , DR , MSC
- Frequency
- Yearly recurring
Examination
- Type
- session examination
- Mode
- written 90 minutes
- Aids
- - non programmable calculator- handwritten notes / 2 DIN A4 pages- A summary of the main equations intorduced in the lecture will be provided for the exam
Course Components
| Type | Title | Time & Place | Hours |
|---|---|---|---|
| lecture | Metal Additive Manufacturing – Fundamentals and Process Technology |
|
2 h weekly |
| exercise | Metal Additive Manufacturing – Fundamentals and Process Technology |
|
2 h weekly |
Offered In
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Design, Mechanics and Manufacturing (Focus Coordinator: Prof. Dennis Kochmann To achieve the required 20 credit points for the Focus Specialization Design, Mechanics and Manufacturing, all of the courses listed can be selected. If required, one course from another focus specialization or from the electives of the ME Bachelor program can be selected. For recommended courses and further information, please visit the MAVT website for Focus Specialization ( ).)
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Core Courses (The Core Courses in the Master’s program Mechanical Engineering listed below are indicative and include courses designed by the Department at the Master's level. With the approval of the tutor, students may also select Master's-level courses offered by other departments at ETH. These courses will be marked as non-regular in the LAG, but their categorization as Core Courses is possible if included in the approved LAG.)
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Doctorate Materials Science (Further information at: )
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