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151-0740-00L 4 Credits BSC , DR , MSC D-MATL , D-MAVT
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Metal Additive Manufacturing – Fundamentals and Process Technology

Lecturers & Examiners: Prof. Dr. Markus Bambach, Dr. Léa Deillon, Dr. Michael Robert Tucker, Dr. Enrico Tosoratti
VVZ CR n/a

Last Updated: 2026-02-05 16:39:07

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: Simulation of AM Processes Unit 7: Laser Powder Bed Fusion - Build Layout Unit 8: Laser Powder Bed Fusion - Process Optimization and Design of Experiments Unit 9: Cost Modeling Unit 10: Machine Architecture Unit 11: Post-processing Unit 12: Materials for Metal AM Unit 13: Powder Fabrication and Characterization Unit 14: Directed Energy Deposition Unit 15: Binder Jetting and sinter-based AM Unit 16: Lightweight Design using AM

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
Grade percentage:- 60%: a final written exam- 40%: compulsory continuous performance assessmentThe compulsory continuous performance assessment tasks need not be passed on its own; it is awarded a grade which counts proportionally towards the total course unit grade.If a student does not submit any of the work for the compulsory continuous performance assessment tasks, then for this part of the performance assessment they will receive the grade “1”.

Course Components

Type Title Time & Place Hours
lecture Metal Additive Manufacturing – Fundamentals and Process Technology
  • Wed 14:15-16:00 (ML E 12)
2 h weekly
exercise Metal Additive Manufacturing – Fundamentals and Process Technology
  • Thu 08:15-10:00 (LFV E 41)
2 h weekly

Offered In