Metal Additive Manufacturing 2

Course Number:
MFG 251
Transcript Title:
Metal Additive Manufacturing 2
Created:
May 06, 2026
Updated:
May 06, 2026
Total Credits:
3
Lecture Hours:
0
Lecture / Lab Hours:
66
Lab Hours:
0
Satisfies Cultural Literacy requirement:
No
Satisfies General Education requirement:
No
Grading Options
A-F, P/NP, Audit
Default Grading Options
A-F
Repeats available for credit:
0
Prerequisites

MFG 250

Course Description

Builds upon metal additive techniques learned in MFG 250, addressing parts with more challenging geometry and learning to generate model preparations as applicable to part geometry. Introduces the printing of multiple parts at once during a build, with focus placed on key changes required when larger thermal mass is present. Practices printing parts with more challenging materials, moving from aluminum to magnesium and titanium, which require changes to powder handling tactics. Explores commonly available post-processing methods to improve the surface finish on printed parts, including tumbling and sandblasting. Prerequisite: MFG 250. Audit available.

Course Outcomes

Upon successful completion of this course, students will be able to:

  1. Apply safe material handling and operating practices for metal additive manufacturing equipment relating to reactive powders.

  2. Maintain metal additive manufacturing equipment and repair common failures.

  3. Program metal additive manufacturing equipment for reactive powder.

  4. Create support and heat-sink strategies to ensure build success and accuracy for more complex geometry.

  5. Apply appropriate post processing strategies for desired finish and fit of parts.

  6. Use comparative analysis to determine the ROI and cost-effectiveness of additive manufacturing compared to other possible manufacturing strategies.

Suggested Outcome Assessment Strategies

The determination of assessment strategies is generally left to the discretion of the instructor. Here are some strategies that you might consider when designing your course: writings (journals, self-reflections, pre writing exercises, essays), quizzes, tests, midterm and final exams, group projects, presentations (in person, videos, etc), self-assessments, experimentations, lab reports, peer critiques, responses (to texts, podcasts, videos, films, etc), student generated questions, Escape Room, interviews, and/or portfolios.

Department recommended assessment strategies:

  • Lecture and in-lab coaching and direct instruction.

  • Full class demonstration of skills.

  • Written exams

  • Student proficiency through demonstration of learned strategies and skills in industry standard environments

  • Job readiness based on performance

  • In class lab experiments and testing using the scientific process with written result reporting

Course Content

Outcome #1: Apply safe material handling and operating practices for metal additive manufacturing equipment relating to reactive powders.

  • Reactive metal powder explosiveness
  • Reactive powder health concerns
  • Reactive metal powder contamination
  • Reactive metal powder MSDS and KST values analysis
  • Reactive metal powder PPE and when to use what PPE
  • Reactive metal powder handling equipment
  • Reactive metal powder processing equipment
  • Safe operation of reactive powder processing equipment

Outcome #2: Maintain metal additive manufacturing equipment and repair common failures.

  • Follow wiring diagrams
  • Troubleshoot PLC systems
  • Follow pneumatic diagrams
  • Replace filters
  • Replace gas cylinders
  • Replace recoater systems
  • Remove and replace build plates
  • Troubleshoot using flow chart
  • Check and/or replace fuses
  • Use digital multi-meter to check electrical connections, amp draws

Outcome #3: Program Metal Additive Manufacturing Equipment for reactive powder.

  • Program metal AM equipment using g-code
  • Write successful metal AM programs
  • Develop print parameters
  • Calibrate different metal powders
  • Check dimensional accuracy against calibrations
  • Maximize powder recovery
  • Safe powder recovery strategies, compare to non-reactive powders

Outcome #4: Create support and heat-sink strategies to ensure build success and accuracy for more complex geometry.

  • Create heat sinks
  • Place melt pools
  • Modify supports to suit geometry
  • Modify geometry to suit metal AM
  • Program complex parts
  • Check success of prints
  • Minimize post processing with successful programming strategy
  • Generate successful programs for complex geometry using a variety of metal support parameters

Outcome #5: Apply appropriate post processing strategies for desired finish and fit of parts.

  • Post process using sandblasting
  • Post process using friction methods
  • Post process using appropriate tumbling media
  • Reduce post processing with programming
  • Post processing for soft materials
  • Post processing for hard materials
  • Strategize post processing for required part parameters
  • Verify success of post processing techniques with equipment

Outcome #6: Use comparative analysis to determine the ROI and cost-effectiveness of additive manufacturing compared to other possible manufacturing strategies.

  • Compare costs using developed data points and expected powder recovery rate and compare to reductive or casting strategies where appropriate
  • Understand the differentiation in total climate carbon offset between additive strategies and other methods of part creation
  • Develop a return on investment cost estimation for the serial creation of parts using an additive strategy as a direct comparison to another chose strategy

Suggested Texts and Materials

Use of listed Texts/Materials is not required unless so noted.

Department Notes

Safety glasses are required at all times in the manufacturing lab, and are provided for students. Students may also purchase their own safety glasses from a local supplier. Long pants and closed toed shoes are required in the manufacturing labs at all times. Appropriate clothing must be worn to work in the lab (no synthetic materials, ect.). Safety requirements are covered prior to work in the lab.