Metal Additive Manufacturing 1

Course Number:
MFG 250
Transcript Title:
Metal Additive Manufacturing 1
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

Course Description

Presents key strategies for success in metal additive manufacturing. Covers the use of data preparation software, starting with simple parts that have additive-friendly geometry. Trains in the operation of DMLS machinery and safe handling and processing of the non-explosive stainless-steel powder used as the material medium. Addresses the material properties of the powder, which inform strategies used during data preparation. Covers key and required supplemental skills, such as ability to operate wire electrical discharge machining equipment and CNC mills for part removal and build plate processing. 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 non-reactive powders.

  2. Perform setup and operation of metal additive manufacturing equipment.

  3. Program metal additive manufacturing equipment for non-reactive powder.

  4. Develop strategies for warp mitigation to hold appropriate tolerance in parts printed with metal additive manufacturing equipment.

  5. Develop strategies and procedures for part removal and for reconditioning of build plate for re-use.

  6. Create basic costing analysis processes for printing of parts.

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 Activities and Design

The determination of teaching strategies used in the delivery of outcomes is generally left to the discretion of the instructor. Here are some strategies that you might consider when designing your course: lecture, small group/forum discussion, flipped classroom, dyads, oral presentation, role play, simulation scenarios, group projects, service learning projects, hands-on lab, peer review/workshops, cooperative learning (jigsaw, fishbowl), inquiry based instruction, differentiated instruction (learning centers), graphic organizers, etc.

Department required activities: Cooperative learning, lecture-lab based experiential learning, guided learning pathways, peer review, hands-on lab, simulation, simulation scenarios, oral presentations.

Course Content

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

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

Outcome #2: Perform setup and operation of metal additive manufacturing equipment.

  • Procedure sheets for clear build communication
  • Data acquisition for relevant data points
  • Machine set up parameters
  • Hand tool preparation for metal printers
  • Build surface preparations strategies
  • Build surface quality checks and controls
  • Build surface leveling processes
  • Powder leveling processes
  • Record appropriate data relating to machine set up

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

  • Use software to create appropriate metal AM files
  • Create geometry useful for metal AM
  • Support structure generation and iteration
  • Powder removal program techniques
  • Post processing with preprocess controls
  • Geometrical understanding of processes

Outcome #4: Develop strategies for warp mitigation to hold appropriate tolerance in parts printed with metal additive manufacturing equipment.

  • Metal pool for metal AM
  • Thermal dynamics applied to Metal
  • Heat sink and raft quality and use
  • Geometry and tolerance as it relates to accuracy
  • Warp mitigation strategies
  • Exposure modification for print quality and tolerance
  • Hardware options for heat warp

Outcome #5: Develop strategies and procedures for part removal and for reconditioning of build plate for re-use.

  • Raft programming
  • Part removal in relation to first layers
  • EDM build plate part removal
  • Friction process build plate removal
  • EDM build plate resurfacing
  • Mill build plate resurfacing
  • Part geometry in regards to part removal from plate

Outcome #6: Create basic costing analysis processes for printing of parts.

  • Powder usage and recovery rates
  • Gas consumption rates
  • Build length
  • Filter consumption rate
  • Recoater consumption rate
  • Cost prediction prior to printing
  • Cost calculation post printing
  • Data tracking for total print costing
  • Comparison of costing to traditional manufacturing techniques

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.