This module investigates the selection and optimization of materials and processes for aerospace additive manufacturing, prioritizing performance-driven material properties. It defines engineering criteria for material compatibility, including strength, thermal resistance, and printability, essential for aerospace demands. The module reviews the use of metals in aerospace AM, highlighting their reliability under extreme conditions. It explores advanced materials specifically developed for AM to enhance component durability and functionality. Process optimization techniques, such as parameter tuning and post-processing, are detailed to improve print quality and performance. The module also analyzes trade-offs between cost, performance, and production speed in material and process selection for aerospace AM.

This module presents practical design strategies for leveraging additive manufacturing to optimize aerospace components. It introduces methods to exploit AM’s capabilities for creating complex, high-performance parts. Advanced topology optimization techniques are explored to reduce weight while maintaining structural integrity. The module discusses selective laser melting (SLM) for producing lightweight, high-strength components through precise material fusion. It introduces tools for automating topology optimization in aerospace design and outlines practical steps for implementing optimized AM designs from concept to production. The suitability of AM for specific aerospace components is evaluated, considering material properties, manufacturing processes, and optimized designs. A concluding video summarizes key learnings and applications of AM in aerospace component design.