The course “Additive Manufacturing of Metallic Components” teaches the theoretical fundamentals of metallic additive manufacturing, particularly using the example of the laser-based process powder bed fusion (PBF-LB/M). It thus provides the ideal prerequisite for the course “Project Internship Additive Manufacturing: Design Optimization and Manufacturing of Metallic Components.”

The course covers the underlying mechanisms and the necessary steps in the additive process chain for metallic components. Other processes for manufacturing metallic components using additive manufacturing methods are also discussed. Students will learn about the following topics:

• Structure and function of a PBF-LB/M system
• Influence of process parameters on the quality of components manufactured in the PBF-LB/M process
• Design for additive manufacturing
• Options for simulation assistance in the process chain
• Process monitoring and quality assurance in additive manufacturing
• Downstream processes for adjusting the required component state
• Quality control in additive manufacturing
• Fundamentals and possibilities of directed energy deposition, binder jetting, and bath-based photopolymerization processes.
  
  

Learning Outcomes:

Students ...

•  are able to explain the basic principles of the laser-based additive manufacturing processes powder bed fusion and directed energy deposition, as well as the two processes binder jetting and bath-based photopolymerization.
• can describe the characteristics and areas of application of the four processes mentioned above.
• can describe the creation of a product along the entire additive process chain (CAD, simulation, construction job preparation, CAM) from the initial idea to production using the example of the powder bed fusion process. 
• are able to discuss the development process for components that are optimized for additive manufacturing.
• can explain in detail the mechanisms behind the powder bed fusion process and derive measures for improving the process. 
• can evaluate and select options for post-processing additively manufactured components based on their requirements. 
• are able to name the most important methods for quality assurance in additive manufacturing and the relevant standards.
  
  

Workload:

regular attendance: 21 hours
self-study: 99 hours

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

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