Metal Additive Manufacturing 3

Course Number:
MFG 252
Transcript Title:
Metal Additive Manufacturing 3
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 251

Course Description

Builds upon metal additive techniques learned in MFG 251. Involves printing parts requiring more specific final dimensions, engaging in more rigorous model preparations required to mitigate problems associated with close tolerance geometry. Explores production strategies to achieve tightly toleranced part dimensions, starting with additive techniques and moving on to reductive finishing methods. Introduces strategies to print at near net shape, with excess material on critical surfaces to be cut with precision reductive CNC machines. Includes printing in highly challenging materials, such as titanium, which require specific powder handling techniques and model preparations due to metallurgical properties such as thermal expansion/contraction, conductivity/dissipation. Prerequisite: MFG 251. Audit available.

Course Outcomes

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

  1. Perform calibration procedures necessary for optimization of accuracy in metal additive manufacturing equipment.
  2. Develop production orientated strategies for large scale longer duration builds.
  3. Use geometry offset planning and requisite math for near-net shape manufacturing of technical parts.
  4. Optimize print efficiency and orientation strategies for complex parts.
  5. Perform root cause analysis of failed or out of tolerance builds, and plan program changes to address them.
  6. Utilize mixed process strategies to produce to tolerance parts, including using reductive post processing programming.

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: Perform calibration procedures necessary for optimization of accuracy in metal additive manufacturing equipment.

  • Run calibration protocols and programs
  • Check calibration results
  • Based on calibrations, make adjustments
  • Verify results of calibrations via testing
  • Measure calibrations
  • Use software compensation for calibration
  • Use hardware adjustments to calibrate equipment
  • Calibrate laser apertures

Outcome #2: Develop production orientated strategies for large scale longer duration builds.

  • Orientate multiple parts on plate
  • Use recoater strategy for success
  • Software for risk mitigation and assessment
  • Maximize volume of build per millimeter height
  • Geometrically align parts for higher success
  • Use soft and hard recoater strategies

Outcome #3: Use geometry offset planning and requisite math for near-net shape manufacturing of technical parts.

  • Modify geometry for success
  • Identify difficult geometry and reorientate to minimize failure
  • Create modelling offsets for metal printing
  • Create programming offsets for metal printing
  • Use algebra to calculate offsets
  • Use trigonometry to calculate offsets
  • Compensate for downskin
  • Support downskin with different strategies

Outcome #4: Optimize print efficiency and orientation strategies for complex parts.

  • Use software to orientate more quickly
  • Optimize prints for consumable efficiency
  • Track print efficiency
  • Record data pertaining to print efficiency
  • Support optimization for build plate removal
  • Support optimization for exterior removal from parts
  • Support optimization for interior removal from parts
  • Geometrical changes for print optimization
  • Geometrical changes for post processing optimization

Outcome #5: Perform root cause analysis of failed or out of tolerance builds, and plan program changes to address them.

  • Inspect a variety of build failures
  • Make corrective actions
  • Analyze changes to print profiles that have failed
  • Consider software reasons for failure
  • Consider hardware reasons for failure
  • Consider consumable, such as powder, reasons for failure
  • Correct build failures by determining reasons for failure
  • Use data from build failures to create a successful and repeatable build program

Outcome #6: Utilized mixed process strategies to produce to tolerance parts, including using reductive post processing programming.

  • Create sacrificial geometry
  • Cut to tolerance with reductive process
  • Cut to tolerance with post processing procedures
  • Post process to save cost when considered with other factors
  • Cut total cost with mixed strategies
  • Program CNC equipment outside of 3d printers to process 3d prints

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.