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The sequence is as follows:

1. Introduction to additive manufacturing
2. Development methodology for additive manufacturing and design of components
3. AM design in the system context – Thinking AM
4. Process induced properties
5. Outline of lightweight design
6. Industrial examples of AM
7. Introduction to lattice structures
8. Manufacturing based design at the mesoscale
9. Analysis and fabrication of strut-based lattice structures
10. The digital process chain for additive manufacturing
11. Life cycle assessment of additively manufactured components
12. Introduction to life cycle assessment (LCA) and carbon footprinting in additive manufacturing
13. Additive manufacturing in the context of Industry 4.0

Exercises:

1. Methodical product development process of AM-parts
2. Design of AM-parts in the system concept
3. Characterization of the mechanical properties of lattice structures under uniaxial compression
4. 3-point bending tests of lattice structures
5. The Digital Process Chain in AM
6. Introduction to LCA for AM components

• Lecture slides of the lecturers
• Lachmayer, R., Lippert, R.B.: Entwicklungsmethodik für die Additive Fertigung, Springer Vieweg 2020
• Lachmayer, R., Rettschlag, K., Kaierle, S.: Konstruktion für die Additive Fertigung, Springer Vieweg 2021
• Lachmayer, R., Bode,B., Kaierle, S.: Innovative Product Development by Additive Manufacturing, Springer Nature, 2022
• Kirchner, E.: Werkzeuge und Methoden der Produktentwicklung: Von der Idee zum erfolgreichen Produkt, Springer Vieweg 2020

The lecture Additive Manufacturing I (Laser Powder Bed Fusion) provides a comprehensive introduction to methods, processes, and applications of metal additive manufacturing. The focus is on the Laser Powder Bed Fusion (PBF-LB/M) process and its complete process chain, covering data preparation, manufacturing, and post-processing. In addition to technological fundamentals, the specific potentials and restrictions of additive manufacturing are addressed.

Key topics include the development and design of additively manufactured components, guidelines and methods of Design for Additive Manufacturing (DfAM), process-induced material and part properties, and system-oriented design principles. Further aspects comprise lightweight design, the role of support and cellular structures, as well as industrial application examples. Moreover, the digital process chain of additive manufacturing is discussed, including sustainability considerations, life cycle assessment, and the integration of AM into the framework of Industry 4.0.

The aim of this course is to enable students to systematically understand additive manufacturing technologies, to evaluate their potentials for product development and production, and to apply them to engineering-related problem-solving.

Information, lecture notes and supplementary materials are available on the e-learning platform Moodle of the course “Additive Manufacturing (Laser-Powder-Bed-Fusion) I“.

The lecture addresses the contribution of additive manufacturing to resource efficiency and sustainability. Students learn how functionally integrated lightweight structures, reduced material consumption, and on-demand production can lead to significant savings in materials and energy. Furthermore, concepts of circular economy, recycling and reuse of powder materials, as well as methods of life cycle assessment (LCA) are discussed to evaluate ecological impacts. The course thus raises awareness for sustainable product development and the role of additive manufacturing in a resource-conscious industry.