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Dhruv Bhate

Powder bed fusion is one of the additive manufacturing processes that has found the most application in functional part production. In this course we discuss this process in the context of polymers (selective laser sintering) and metals (laser powder bed fusion), with an emphasis on machine setup and post-processing.

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Powder bed fusion is one of the additive manufacturing processes that has found the most application in functional part production. In this course we discuss this process in the context of polymers (selective laser sintering) and metals (laser powder bed fusion), with an emphasis on machine setup and post-processing.

The necessary elements for each course are lecture videos, knowledge checks, and project completion. For additional information on certain topics, I've included supplemental readings and videos throughout various lessons that might enhance your knowledge. Because all resources are not available to all students, these materials are purely optional.

In addition, you will note that some of the lectures feature our department’s graduate students. These excellent students are sometimes closer to the material, having learned it recently, so we greatly appreciate their participation in the instructional process.

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What's inside

Syllabus

Course Introduction
Powder bed fusion is one of the additive manufacturing processes that has found the most application in functional part production. In this course we discuss this process in the context of polymers (selective laser sintering) and metals (laser powder bed fusion), with an emphasis on machine setup and post-processing. The necessary elements for each course are lecture videos, knowledge checks, and project completion. For additional information on certain topics, I've included supplemental readings and videos throughout various lessons that might enhance your knowledge. Because all resources are not available to all students, these materials are optional. In addition, you will note that some of the lectures feature our department’s graduate students. These excellent students are sometimes closer to the material, having learned it recently, so we greatly appreciate their participation in the instructional process.
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Module 4.1: Selective Laser Sintering
This module introduces you to selective laser sintering.
Module 4.2: Metal Laser Powder Bed Fusion
This module introduces you to metal laser powder bed fusion.
Module 4.3: Course Project and Wrap-Up
A crucial step in qualifying any metal additive manufacturing process is establishing the density of the 3D-printed parts. In this module, you will learn how density is measured using a technique known as the Archimedes method, and you’ll learn how that data is correlated back to the process.

Good to know

Know what's good
, what to watch for
, and possible dealbreakers
Examines selective laser sintering and metal laser powder bed fusion, which are in-demand in manufacturing
Provides hands-on experience through a project
Emphasizes machine setup and post-processing, which are crucial aspects of these processes
Offers supplemental readings and videos for deeper exploration, enhancing knowledge acquisition
Taught by instructors with real-world expertise
Graduate students contribute to the instructional process, bringing a fresh perspective

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Activities

Be better prepared before your course. Deepen your understanding during and after it. Supplement your coursework and achieve mastery of the topics covered in Selective Laser Sintering and Metal Laser Powder Bed Fusion with these activities:
Review Additive Manufacturing Concepts
Ensure you have a strong foundation by reviewing the basics of additive manufacturing, including the different techniques and their applications.
Browse courses on Additive Manufacturing
Show steps
  • Read introductory articles or textbooks on additive manufacturing.
  • Watch online videos or tutorials on the basics of 3D printing.
  • Review key concepts such as layer-by-layer deposition, build volume, and materials used.
Review Powder Bed Fusion Basics
Improve understanding of fundamental concepts and processes in preparation for the course.
Show steps
  • Read through the introductory course materials on powder bed fusion.
  • Familiarize yourself with the different types of powder bed fusion processes.
  • Review the basic principles of laser-based powder bed fusion.
Participate in a Study Group for Powder Bed Fusion
Collaborate with peers to enhance understanding and problem-solving skills.
Show steps
  • Find or form a study group with other students taking the course.
  • Schedule regular meetings to discuss course materials, assignments, and projects.
  • Work together to solve problems, clarify concepts, and support each other's learning.
Nine other activities
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Show all 12 activities
Learn about Selective Laser Sintering
Gain practical insights into the process and its applications.
Show steps
  • Follow online tutorials on the principles of selective laser sintering.
  • Explore case studies and examples of SLS applications.
  • Read technical articles or white papers on the topic.
Master Selective Laser Sintering Techniques
Delve deeper into the practical aspects of selective laser sintering by following guided tutorials.
Show steps
  • Find online tutorials or training programs on SLS.
  • Set up a virtual or physical SLS printer (if available).
  • Practice designing and slicing models for SLS printing.
  • Experiment with different materials and parameters to optimize print quality.
Attend a Workshop on Advanced Powder Bed Fusion Techniques
Gain hands-on experience and learn about cutting-edge developments.
Show steps
  • Research and identify relevant workshops in the field of powder bed fusion.
  • Register for the workshop and make arrangements for attendance.
  • Attend the workshop and actively participate in sessions.
  • Connect with experts and industry professionals.
Practice Designing Parts for Laser Powder Bed Fusion
Enhance design skills by applying principles learned in the course to practical scenarios.
Show steps
  • Use CAD software to create 3D models of parts suitable for laser powder bed fusion.
  • Simulate the printing process using software tools.
  • Analyze the results and iterate on the design to optimize printability.
Refine Metal Laser Powder Bed Fusion Skills
Sharpen your skills in metal laser powder bed fusion through repetitive exercises.
Show steps
  • Practice designing models for LPBF printing.
  • Simulate and optimize printing parameters for various materials.
  • Troubleshoot common issues encountered in LPBF.
  • Conduct post-processing steps such as heat treatment and surface finishing.
Develop a Project Plan for a Powder Bed Fusion Project
Apply knowledge and skills to plan a comprehensive powder bed fusion project.
Show steps
  • Define the project scope, objectives, and deliverables.
  • Research and identify appropriate materials and processes.
  • Plan the production timeline, budget, and quality control measures.
  • Prepare a project proposal or presentation.
Design and 3D Print a Custom Part
Apply your knowledge by designing and 3D printing a custom part using either selective laser sintering or metal laser powder bed fusion.
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Show steps
  • Identify a problem or need that can be solved with a 3D-printed part.
  • Design the part using CAD software.
  • Choose the appropriate additive manufacturing technique and materials.
  • Print the part and conduct post-processing.
  • Test and evaluate the part's performance.
Contribute to an Open-Source Powder Bed Fusion Project
Gain practical experience and connect with the wider powder bed fusion community.
Show steps
  • Identify an open-source powder bed fusion project of interest.
  • Join the project community and contribute to discussions.
  • Report bugs, suggest improvements, or contribute code to the project.
Write a Technical Report on Powder Bed Fusion
Synthesize your knowledge by writing a comprehensive technical report that summarizes the principles, applications, and challenges of powder bed fusion.
Browse courses on Technical Writing
Show steps
  • Research and gather information from credible sources.
  • Outline the report structure and organize your content.
  • Write the report, including an introduction, literature review, methodology (if applicable), results, discussion, and conclusion.
  • Review and edit your report for clarity and accuracy.

Career center

Learners who complete Selective Laser Sintering and Metal Laser Powder Bed Fusion will develop knowledge and skills that may be useful to these careers:
Manufacturing Engineer
Manufacturing Engineers need to have a strong understanding of the principles of manufacturing processes, including both traditional and additive manufacturing techniques. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Manufacturing Engineers with valuable knowledge about how to use these advanced manufacturing techniques to improve the efficiency and effectiveness of their manufacturing operations.
Materials Scientist
Materials Scientists need to have a strong understanding of the properties of materials and how they are affected by processing. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Materials Scientists with valuable knowledge about how these advanced manufacturing techniques can be used to create new materials with tailored properties for use in a variety of applications.
Aerospace Engineer
Aerospace Engineers need to have a strong background in physics and engineering principles that govern the design and manufacture of aircraft, spacecraft, satellites, and missiles. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can help build a foundation for this type of work by providing knowledge about the latest manufacturing techniques used in the aerospace industry. Additionally, this course can provide Aerospace Engineers with valuable insights into how to improve the design and production of lightweight, durable components for use in aerospace applications.
Mechanical Engineer
Mechanical Engineers need to have a strong understanding of the principles of mechanical engineering, including the design and analysis of mechanical systems. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Mechanical Engineers with valuable knowledge about how these advanced manufacturing techniques can be used to create new and improved mechanical components.
Product Designer
Product Designers need to have a strong understanding of the principles of design and how to create products that are both functional and aesthetically pleasing. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Product Designers with valuable knowledge about how these advanced manufacturing techniques can be used to create innovative new products.
Research Scientist
Research Scientists need to have a strong understanding of the scientific method and how to conduct research. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Research Scientists with valuable knowledge about how these advanced manufacturing techniques can be used to conduct research in a variety of fields.
Technical Writer
Technical Writers need to have a strong understanding of technical concepts and how to communicate them clearly and concisely. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Technical Writers with valuable knowledge about how these advanced manufacturing techniques can be used to create clear and informative technical documentation.
Teacher
Teachers need to have a strong understanding of the subject matter they are teaching and how to effectively communicate that information to students. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Teachers with valuable knowledge about how these advanced manufacturing techniques can be used to create engaging and informative lessons for students.
Quality Control Inspector
Quality Control Inspectors need to have a strong understanding of quality control principles and how to inspect products to ensure that they meet specifications. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Quality Control Inspectors with valuable knowledge about how these advanced manufacturing techniques can be used to improve the quality of manufactured products.
Maintenance Technician
Maintenance Technicians need to have a strong understanding of how to maintain and repair equipment. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Maintenance Technicians with valuable knowledge about how these advanced manufacturing techniques can be used to maintain and repair equipment more efficiently and effectively.
Sales Engineer
Sales Engineers need to have a strong understanding of the products they are selling and how to communicate their benefits to customers. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Sales Engineers with valuable knowledge about how these advanced manufacturing techniques can be used to create innovative new products that meet the needs of customers.
Project Manager
Project Managers need to have a strong understanding of how to plan, execute, and close projects. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion can provide Project Managers with valuable knowledge about how these advanced manufacturing techniques can be used to improve the efficiency and effectiveness of their projects.
Business Analyst
Business Analysts need to have a strong understanding of business processes and how to improve them. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion may provide Business Analysts with valuable knowledge about how these advanced manufacturing techniques can be used to improve the efficiency and effectiveness of business processes.
Financial Analyst
Financial Analysts need to have a strong understanding of financial principles and how to analyze financial data. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion may provide Financial Analysts with valuable knowledge about how these advanced manufacturing techniques can be used to improve the efficiency and effectiveness of financial analysis.
Marketing Manager
Marketing Managers need to have a strong understanding of marketing principles and how to develop and implement marketing campaigns. This course in Selective Laser Sintering and Metal Laser Powder Bed Fusion may provide Marketing Managers with valuable knowledge about how these advanced manufacturing techniques can be used to create innovative new products and services that meet the needs of customers.

Reading list

We've selected six books that we think will supplement your learning. Use these to develop background knowledge, enrich your coursework, and gain a deeper understanding of the topics covered in Selective Laser Sintering and Metal Laser Powder Bed Fusion.
This comprehensive textbook provides a solid overview of the principles and practices of additive manufacturing technologies, including selective laser sintering and metal laser powder bed fusion. It is an excellent resource for gaining a foundational understanding of these processes and their applications.
This comprehensive textbook covers the principles and practices of additive manufacturing and 3D printing technologies, including selective laser sintering and laser powder bed fusion. It valuable resource for engineers and researchers working with these technologies.
This textbook provides a comprehensive overview of additive manufacturing of metals, including selective laser sintering and laser powder bed fusion. It covers the entire process chain, from design to production.
Provides a comprehensive overview of powder metallurgy of titanium alloys, including the use of powder bed fusion. It valuable resource for anyone who wants to learn more about the use of this material in additive manufacturing.
Focuses on additive manufacturing for the aerospace industry. It covers the principles, materials, processes, and applications of these technologies.
This undergraduate textbook provides a broad overview of modern manufacturing processes, including selective laser sintering and laser powder bed fusion. It good resource for students who want to gain a foundational understanding of these processes.

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