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This Open Educational Resource (OER) module delivers a rigorous curriculum unit on industrial qualification pipelines, certification standards, life-cycle economics, and cross-sectoral case studies for structural metal additive manufacturing (AM).

Covering Laser Powder Bed Fusion (LPBF) and Electron Beam Melting (EBM) of flight-critical aerospace alloys (Ti-6Al-4V) and bio-compatible medical implants, the module analyzes:1. Aerospace Buy-to-Fly (BTF) ratio reductions (from 15:1 CNC billet milling down to 1.5:1 via LPBF).2. Structural topology optimization using Solid Isotropic Material with Penalization (SIMP) formulations for compliance minimization.3. Patient-matched cranial and orthopaedic devices designed under ISO 13485 / FDA pathways with trabecular lattice grading to alleviate stress shielding (Gibson-Ashby mechanics).4. Raw feedstock rheology, particle size distribution (PSD), and non-destructive quality evaluation via industrial X-ray micro-computed tomography (micro-CT per ASTM E1441 / ASTM F3049).

Pedagogical alignment satisfies Washington Accord Graduate Attributes WA1 (Engineering Knowledge), WA2 (Problem Analysis), WA3 (Design/Development of Solutions), and WA5 (Modern Tool Usage).

Published online at Prep4Uni.Online:https://prep4uni.online/stem/physical-technologies/industrial-and-manufacturing-technologies/additive-manufacturing-3d-printing/industry-applications-case-studies/

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