This course provides students with the latest knowledge and skills for metal Additive Manufacturing (AM) providing a great foundation for a future career. This includes AM processes and their capabilities, designing AM systems, qualification, modelling and materials. Practical experience will be gained through assignments and group and individual projects in close collaboration with leading industrial end-users.

Overview

  • Start dateFull-time: October. Part-time: throughout the year
  • DurationMSc: Full-time one year Part-time up to three years; PgDip: Full-time up to one year Part-time two years; PgCert: Full-time up to one year Part-time two years.
  • DeliveryTaught modules 40%, Group project 20% (dissertation for part-time students), Individual project 40%
  • QualificationMSc, PgDip, PgCert
  • Study typeFull-time / Part-time
  • CampusCranfield campus


Who is it for?

Cranfield University offers the MSc course in order to deliver graduates who are able to hold positions of significant engineering responsibility in the wide range of organisations using Metal Additive Manufacturing Technologies. This course provides students with the latest knowledge and skills for metal Additive Manufacturing (AM) providing a great foundation for a future career. This includes AM processes and their capabilities, designing AM systems, qualification, modelling and materials. Practical experience will be gained through assignments and group and individual projects in close collaboration with leading industrial end users.  The graduate will meet a major part of the requirements for membership of the appropriate professional organisations, and will have experience and skills in the management of research and development projects.

Why this course?

Cranfield University has over 20 years’ experience in large-scale AM of metallic structures on all fronts i.e. process design; incorporation of ancillary processes (cold work, metrology, inspection); development of specialist hardware and CAM software; qualification of material properties and definition of design and manufacturing rules. 

Our ever-growing materials portfolio features alloys such as titanium, aluminium, iron, nickel and copper-based systems as well as exotic elements such as tungsten, molybdenum, and tantalum.

Access is given to several state-of-the-art AM facilities including Wire + Arc AM systems (based on robotic arms), CNC gantries, laser-wire AM systems and powder-based systems.

Did you know we have the biggest metal 3D printer? 3D printing also known as additive manufacture (AM), enables the production of metal parts at significantly reduced time and cost when compared to existing methods. 

You will join a teaching and research team of approximately 30 people, and will have the chance to work on projects within the WAAMMat consortium. This currently includes 20 industry partners (including Airbus, BAE SYSTEMS, Lockheed Martin, etc).

More details here waammat.com

The development of this new course has been co-funded by the Erasmus+ programme.

erasmus logo


Informed by Industry

This course has been designed in close collaboration with Cranfield’s industrial partners. They will continue to help to develop sponsored projects, as well as updating the content of the course in alignment with what’s needed by industry.


Course details

The course includes nine taught compulsory modules, which are generally delivered from October to March. Module titles include:

  • Additive Manufacturing System Design
  • Finite Element Analysis (theory and hands-on experience on FEA)
  • General Management
  • Management of Manufacturing Quality (defects, standards, procedures, statistical control)
  • Metal Additive Manufacturing Processes (an overview of the technologies used in metal AM)
  • Metal Additive Manufacturing Metallurgy (will provide an understanding of micro-structures and metallurgical characteristics of various alloy systems deposited by AM).
  • Net-shape Manufacturing (a closer look at the net-shape AM processes ,plus others)
  • Post-processing for AM (understanding and selecting the most appropriate post-processing techniques)

The modules include lectures and tutorials, and are assessed through practical work, written examinations, case studies, essays, presentations and tests. These provide the 'tools' required for the group and individual projects.



Course delivery

Taught modules 40%, Group project 20% (dissertation for part-time students), Individual project 40%

Group project

The group project experience is highly valued by both students and prospective employers. Teams of students work to solve an industrial problem. The project applies technical knowledge and provides training in teamwork and the opportunity to develop non-technical aspects of the taught programme. Part-time students can prepare a dissertation on an agreed topic in place of the group project.

Industrially orientated, our team projects have support from external organisations. As a result of external engagement, Cranfield students enjoy a higher degree of success when it comes to securing employment. Prospective employers value the student experience where team working to find solutions to industrially based problems are concerned.

Example of recent group projects from related courses include:

  • WAAM of 15-5 PH stainless steel using Plasma arc process
  • In-process cold-work of WAAMed aluminium to eliminate porosity
  • Laser Interferometric Technology to Monitor Additive Manufacturing

Individual project

Students select the individual project in consultation with the Course Director. The individual project provides students with the opportunity to demonstrate their ability to carry out independent research, think and work in an original way, contribute to knowledge and overcome genuine problems.

Example of recent individual thesis projects from related courses include:

  • Electrical property characterisation of copper and aluminium components made by additive manufacturing
  • Relationships between build rate and mechanical properties in Ti-6-Al-4V
  • Study of building horizontal and inclined walls using additive layer manufacture


Modules

Keeping our courses up-to-date and current requires constant innovation and change. The modules we offer reflect the needs of business and industry and the research interests of our staff and, as a result, may change or be withdrawn due to research developments, legislation changes or for a variety of other reasons. Changes may also be designed to improve the student learning experience or to respond to feedback from students, external examiners, accreditation bodies and industrial advisory panels.

To give you a taster, we have listed the compulsory and elective (where applicable) modules which are currently affiliated with this course. All modules are indicative only, and may be subject to change for your year of entry.


Course modules

Compulsory modules
All the modules in the following list need to be taken as part of this course.

Metal Additive Manufacturing Processes

Aim
    The aim of this module is to provide the student with a description of the physical principles, operating characteristics and practical applications of a variety of metal Additive Manufacturing processes to enable selection of a suitable process for a particular application.
Syllabus
    • Plasma/TIG/MIG deposition
    • Laser processing
    • Laser blown powder
    • Laser wire deposition
    • Electron Beam deposition
    • AM process selection
    • Distortion control methods
    • Defects and how to avoid them
    Please note that a part of this module is shared with I-WEE-WPE Welding Processes and Equipment
Intended learning outcomes

On successful completion of this module a student should be able to:
1. Compare different AM processes and describe the machine architecture.
2. Evaluate different AM processes for a specific application.
3. Propose methods to reduce distortion for a variety of part geometries and processes.
4. Diagnose the cause of defects and propose methods for their mitigation.

Post Processing for Additive Manufacturing

Aim
    This module will enable students to understand, describe and evaluate the different post processing techniques currently used on AM parts and allow them to select the most appropriate one for a specific AM process and application. It will explore the underlying material science concepts for these processes.
Syllabus
    • Post-processing techniques.
    • Shot-peening
    • heat treatments
    • Hot isostatic pressing
    • Materials science
Intended learning outcomes

On successful completion of this module a student should be able to:
1. Evaluate the different post processing techniques used on AM parts, including those required for removal of support structures, improvement of surface characteristics and structural integrity.
2. Appraise the benefits and limitations of each post processing technique with respect to each AM process.
3. Propose the most suitable post processing technique for a specific AM process and application.
4. Assess the benefits of in-process cold work on the properties and microstructure of parts.

Metal Additive Manufacturing Metallurgy

Aim
    The aim of this module is to provide the student with an understanding of the microstructures and metallurgical characteristics of Additively Manufactured (AM) structures in a range of alloys, and how the metal and heat source interaction affects microstructure and strengthening behaviour of different alloys.
Syllabus
    • Mechanical properties of metals
    • Dislocations and strengthening mechanisms
    • Failure
    • Grain structure and recrystallisation
    • Phase Diagrams
    • Phase transformations: Development of microstructure and alteration of mechanical properties
    • Principles of metallographic examinations
    • Steel/Stainless Steels/Nickel
    • Aluminium, copper, and other non-ferrous alloys
    • Titanium
    • Heat treatments
    • Dissimilar AM
    • Corrosion

    Please note that part of this module is shared with the I-WEE-A1103 Welding Metallurgy one
Intended learning outcomes

On successful completion of this module a student should be able to:
1. Analyse phase diagrams and continuous temperature transformation diagrams for a range of alloys to explain the microstructural changes that occur.
2. Relate material microstructure to mechanical performance.
3. Evaluate specific materials for different applications to ensure they meet the requirements of the design brief.
4. Relate the heat treatment to the microstructure, mechanical properties, residual stress and defects.
5. Compose procedures and methods for preventing formation of undesirable phases and defects for dissimilar metallic AM parts.

Management of Manufacturing Quality

Aim
    The aim of this module is to provide the student with an understanding of the fundamentals of quality management related to additive manufacturing, welding, and other processes, including quality systems and non-destructive examination, and to provide the student with the knowledge to manage health and safety in the work place.
Syllabus
    • Overview of standards and their function
    • Introduction to quality assurance
    • Quality control during manufacture
    • Welder and operator qualification
    • Introduction to Non-destructive examination (NDE) and types of defects
    • Destructive testing methods
    • Non-destructive testing methods (dye penetrant, magnetic particle, eddy current, acoustic emission, radiographic inspection, tomography, ultrasonic inspection)

Intended learning outcomes
On successful completion of this module a student should be able to:
1. Appraise the standards and the relationship between standards and a particular application, to achieve the required quality;
2. Assess the different NDT techniques, explain the principles upon which they are based, and interpret their results
3. Assess the probability of occurrence of the different defect types for a selection of materials and manufacturing techniques
4. Manage workplace practices to ensure adequate health and safety.

Additive Manufacturing System Design

Aim

    This module will enable students to design their own additive manufacturing cell (including manipulation equipment, and sensing), or integrate an existing additive manufacturing machine in a broader production line. It also introduces the student to experimental design and how to develop suitable parameters for part production.


Syllabus
    • Sensors for Additive manufacturing.
    • Manipulation
    • Jigs and fixtures
    • Cell design
    • Project planning
    • Factory layout
    • Experimental design
    • Part shielding
    • Thermal management
    Please note that part of this module is shared with the WSRM-Welding Systems and Research Methods.
Intended learning outcomes

 On successful completion of this module a student should be able to:

1. Design and justify a programme of experiments for producing a simple structure and demonstrate the effect of the main input parameters, and analyse data produced from these experiments so that the relationship between process inputs and outputs is understood.

2. Plan an AM cell for manufacturing a specific AM part that includes selection of a robot, and methods to manipulate the part, fixturing and sensing of the part, equipment for loading and unloading, labour requirements and an estimation of the time to manufacture.

3. Calculate and justify the cost of a typical additive manufacturing operation including labour costs, overhead costs, and consumable costs.

4. Plan a factory layout that incorporates all required operations (feedstock storage, machine preparation, material preparation, AM cell and the finishing operations for the part).

5. Construct a project plan for the installation of the AM system.

Net-Shape Manufacturing

Aim
    This module will introduce the state-of-art of various net-shape manufacturing techniques: including various powder processing techniques; selective laser melting, electron beam melting, hot isostatic pressing, as well as casting and forming. The mechanisms of individual techniques will be explored to include the benefits, challenges, limitations and suitability of each process. Practical examples will be used throughout.
Syllabus
    • Powder Processing – SLM, EBM and HIP
    • Net-shape manufacturing
    • Materials science

Intended learning outcomes

On successful completion of this module a student should be able to:
1. Evaluate the applicability of net-shape manufacturing processes: SLM, EBM, hot Isostatic pressing, casting, forming, powder processing as a complement or substitute of AM.
2. Appraise the benefits, challenges and limitations associated with the use of net-shape manufacturing techniques.
3. Propose a suitable net-shape manufacturing process for fabricating shapes and structures.
4. Compose the process requirements and parameters, based on the characteristics of the net-shape manufacturing process.

Teaching team

You will be taught by industry-active research academics from Cranfield with an established track record, supported by visiting lecturers from industry. The Course Director for this programme is Dr Filomeno Martina and the Admissions Tutor for this programme is Dr Iva Chianella.

Your career

This qualification takes you on to a wide range of careers involving metal additive manufacturing processes, with experts needed in all fields from design, processes or simulation. Responsibilities include research, development, design, engineering, consultancy and management across a broad range of industrial sectors.

Cranfield Careers Service

Our Careers Service can help you find the job you want after leaving Cranfield. We will work with you to identify suitable opportunities and support you in the job application process for up to three years after graduation. Our strong reputation and links with potential employers provide you with outstanding opportunities to secure interesting jobs and develop successful careers.

How to apply

Online application form. UK students are normally expected to attend an interview and financial support is best discussed at this time. Overseas and EU students may be interviewed by telephone.