The course “Project Course Additive Manufacturing: Design Optimization and Production of Metallic Components” combines the fundamentals of powder bed fusion laser beam melting (PBF-LB/M) with a development project in collaboration with an industry-relevant application case.

Students learn the basics of the following topics:

• Influence of various process variables on the component quality of parts manufactured using the PBF-LB/M process
• Preparation and simulation of the PBF-LB/M process
• Manufacturing of additive metal components
• Process monitoring and quality assurance in additive manufacturing
• Topology optimization
• Computer-aided manufacturing (CAM) for machining rework

The topics are demonstrated in practice in various workshops on the individual topics and transferred to the development task in teamwork. Finally, the results of the work are additively manufactured and machined. The results are then presented, reflected upon, and discussed.

Attendance of the course “Additive Fertigung metallischer Bauteile” is recommended.

Learning Outcomes:

Students ...

• can describe the characteristics and areas of application of the additive manufacturing process powder bed fusion of metals (PBF-LB/M).
• can describe and implement the creation of a product along the entire additive process chain (CAD, simulation, construction job preparation, CAM) from the initial idea to production.
• are able to discuss the development process for components that are optimized for additive manufacturing.
• are able to perform topology optimization of a component for manufacturing using additive manufacturing.
• are able to simulate the additive process, compensate for process-related distortion, and determine the ideal alignment on the build platform.
• are able to create the necessary support structures for the additive process and derive a build job file.
• are able to create a CAM model for the machining post-processing of additive components and to machine the component.
• can select suitable powder fractions and process variables for the additive manufacturing of high-quality components based on existing test results.

Workload:

regular attendance: 21 hours
self-study: 99 hours

Skript zur Veranstaltung wird über (https://ilias.studium.kit.edu/) bereitgestellt.

Lecture notes will be provided in Ilias (https://ilias.studium.kit.edu/).

Das Praktikum wird erstmals im Sommersemester 2026 angeboten.

Unregelmäßige Termine, siehe Zeitplan auf wbk-Homepage.
Irregular dates, see schedule on the wbk homepage.