Examine the technology and characteristics of additive manufacturing processes as used in industry

Powder bed fusion – electron beam melting, laser powder bed, plasma powder bed, laser sintering

Photo polymerization – Selective Laser Sintering (LS), stereolithography (SLA), Digital Light Processing (DLP)

Material jetting – binder jetting

Wire deposition (wire arc manufacturing), including plasma, electron beam and laser.

All You Need to Know About Unit 45: Additive Manufacturing Processes

Unit 45: Additive Manufacturing Processes explores the world of additive manufacturing, better known as 3D printing. This is not just another production technique – it is a step towards the future of how products are designed, tested, and created. Instead of removing material like in traditional machining, additive manufacturing builds parts layer by layer. This approach makes it possible to create complex shapes, lightweight structures, and highly customised designs that would otherwise be too expensive or impossible to produce.

The unit gives learners the chance to understand how industries are adopting these methods to speed up innovation. From producing life-saving medical implants to reducing the weight of aerospace components, additive manufacturing is proving its value in many different sectors. It encourages learners to think about efficiency, sustainability, and creativity in production, rather than sticking to conventional limits.

Studying unit 45 also helps learners connect technology with real business advantages. Additive manufacturing cuts waste, shortens product development cycles, and allows companies to respond quickly to customer needs. For learners, this means gaining insight into both the technical process and the competitive edge it brings to modern industries.

Our Expert`s Advice for Unit 45

• Show that you understand the idea of additive manufacturing in your own words, not copied from books or online sources.

• Write as if you are explaining the topic to someone new, keeping the language simple and clear.

• Focus on what you have learnt as a student – for example, how this unit made you think differently about modern manufacturing.

• Use examples that connect to your studies (e.g., how 3D printing is used for models, prototypes, or real-life products).

• Discuss both strengths and weaknesses of additive manufacturing, showing that you can think critically.

• Keep your work structured like an academic piece: short intro → main discussion → applications/benefits → challenges → conclusion.

• Make the assignment personal to your learning journey – show how this knowledge could help you in future studies or jobs.

Sample Answer of Unit 45: Additive Manufacturing Processes Assignment

Examine the technology and characteristics of additive manufacturing processes as used in industry

You need to identify at least two engineered products that are produced using different additive manufacturing (AM) processes and carry out research into: The technology and characteristics of the identified AM processes, including complexity, surface texture and tolerances.

Introduction

Additive manufacturing (AM) is a modern way of making components by building them layer upon layer, instead of cutting them from a solid block. This approach has changed how engineers design and test products, especially when creating prototypes or small batches. In this report, I will look at two different processes: Fused Deposition Modelling (FDM) and Selective Laser Sintering (SLS). I will explain how they work, the kind of parts they produce, their advantages, and the issues linked to safety and sustainability.

Technology and Characteristics

Fused Deposition Modelling (FDM)

• How it works: Plastic filament is melted and pushed through a nozzle. The machine moves in set paths to build the part layer by layer.

• Part detail: Shapes are accurate but layers can be seen on the surface. Extra supports are often needed for certain angles.

• Tolerances: Reasonable for prototypes and everyday items, but not always good enough for very high-precision parts.

• Machine size and speed: Machines are small compared to other AM types, and usually slower for larger or detailed parts.

Selective Laser Sintering (SLS)

• How it works: A fine layer of powdered material (often nylon) is spread over the build area. A laser beam scans the powder and fuses it where the part should be. Layers are added until the product is complete.

• Part detail: Surfaces are smoother than FDM, and shapes can be very complex without the need for support structures.

• Tolerances: Higher accuracy than FDM, making it suitable for functional prototypes and some end-use parts.

• Machine size and speed: The machines are larger and cost more, but they can make several parts in one build, which saves time overall.