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Metal Additive Manufacturing – Fundamentals and Process Technology
Last Updated: 2026-02-05 15:54:31
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
Synopsis 1. Introduction / motivation 2. From fusion welding to AM (Basics of fusion welding, moving heat sources, melt pool dynamics, solidification of weld beads, part properties) 3. Wire-arc Additive Manufacturing (Process technology, Digital process chain: Slicing and process definition, Overlapping weld beads, Sensors and control, materials for WAAM) 4. Laser-based metal additive manufacturing I – Basics of laser technology (Laser principles, Gaussian beams and beam quality, Inteaction laser-material / laser-plasma) 5. Laser-based metal additive manufacturing II – Laser powder bed fusion (Process technology, digital process chain, parameters and properties, support structures, process control, applications & trends) 6. Laser-based metal additive manufacturing III – Laser-based directed Energy deposition (Process technology, digital process chain, Sensors & control, materials, applications & trends) 7. Electron beam based AM (Process technology, b. Interaction electron beams – matter, sensors & control, materials, applications & trends) 8. Binder Jetting / Sintering based AM (Process technology, Sinter theory, compensation of shrinkage, applications) 9. Post-processing (removal of supports, hot isostatic pressing, Machining / Finishing) 10. Materials for AM (Alloy systems for AM, Production and quality of powder, Computational materials design) 11. Future trends (Multi-material AM, Hybrid AM processes, ...)
Resources
Lecture Notes
The lecture slides will be distributed.
Literature
A list of references be given in the lecture.
General Information
- Language
- English
- Levels
- BSC , MSC
- Frequency
- Yearly recurring
Examination
- Type
- session examination
- Mode
- written 90 minutes
- Aids
- None
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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Manufacturing Science (Focus Coordinator: Prof. Konrad Wegener To achieve the required 20 credit points for the focus specialization you need to pass all 3 compulsory courses (HS/FS). The other 8 credit points can be achieved from the elective courses.)
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Mechanics, Materials, Structures (The courses listed in this category “Core Courses” are recommended. Alternative courses can be chosen in agreement with the tutor.)
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