Short Description

Aligned with EQF Level 5, this online course addresses the strategic role of Additive Manufacturing (AM) in advancing the aerospace sector's green and digital transition through lightweighting and manufacturing efficiency. Learners acquire essential knowledge in workshop safety protocols for reactive metal powders and engineering polymers, alongside practical digital slicing and support structure optimization. The core focus is placed on critical post-processing operations, including part separation (wire EDM/sawing), thermal stress relief heat treatments, and advanced surface finishing techniques.

Thematic Area

Aeronautics (incl. manufact. & quality systems)

Target Audience

VET Learners

Entry Requirements

Basic digital skills required

Learning Objectives

In the end, learners will be able to:

• Explain the strategic importance of Additive Manufacturing in aerospace lightweighting and apply strict workshop OHS protocols when handling reactive metal powders and high-performance polymers.

• Compare core aerospace AM technologies (PBF and DED) and select appropriate aerospace-grade alloys (e.g., Titanium, Inconel) or polymers (e.g., PEEK) based on component requirements.

• Configure digital slicing parameters (orientation, layer thickness, infill) and design optimal support structures to prevent warping and thermal distortions.

• Select and plan suitable part separation methods from the build plate (manual sawing vs. Wire EDM) and perform mechanical support removal and powder cleaning.

• Determine proper stress relief heat treatment cycles to eliminate residual internal stresses and apply advanced surface finishing techniques (bead blasting, chemical vapor smoothing).

Key Outcomes and Competences developed

1. Key Outcomes (Knowledge, Skills, Autonomy & Responsibility)

Knowledge: Comprehensive operational understanding of Additive Manufacturing (AM) workflows in aerospace, including Powder Bed Fusion (PBF) and Directed Energy Deposition (DED) principles, properties of aerospace alloys (Titanium, Inconel) and engineering polymers (PEEK), thermal stress dynamics, and strict workshop health and safety (OHS) regulations.

Skills: Practical proficiency in configuring digital slicing parameters, designing optimized support structures to mitigate warping, selecting and planning mechanical part separation methods (Wire EDM / sawing), and executing thermal stress relief and advanced surface finishing procedures (bead blasting, vapor smoothing).

Level of Autonomy and Responsibility (EQF Level 5): Learners demonstrate comprehensive operational autonomy in supervising build preparation and post-processing sequences, exercising judgment and troubleshooting capabilities during process deviations, and taking personal responsibility for adherence to workshop safety and environmental protocols without direct supervision.
 

2. Competences Developed (ESCO Taxonomy Aligned)

Technical Competences:

Additive manufacturing technologies (ESCO: operate 3D printers / additive manufacturing)

Digital manufacturing & build preparation (ESCO: use 3D printing software / configure slicing software parameters)

Occupational safety & hazardous materials handling (ESCO: apply health and safety standards / handle metal powders safely / wear personal protective equipment)

Mechanical part separation & machining (ESCO: operate wire electrical discharge machines / cut metal workpieces)

Thermal processing (ESCO: perform heat treatment / execute stress relief annealing)

Surface finishing & treatment (ESCO: perform surface finishing / operate sandblasting equipment / apply chemical finishing)

Main Contents

Module 1: Introduction AM, Strategic Role & OHS Safety

Module 2: AM Technologies

Module 3: Digital Build Preparation and Slicing Parameters

Module 4: Mechanical Post-Processing and Part Separation

Module 5: Aerospace Applications

Level of Complexity

Intermediate

Delivery Mode

Online, Self-paced

Estimated Workload

20 hours (Asynchronous)

Instructor

Alperen Dogru

Host Institution

EGE

Certification Type

Microcredential

Endorsement/Awarding Body

WAM - World Alliance for Microcredentials

Indicative EQF Level

EQF level 5

Number of Modules

5

Assessment Methods and Approval Criteria

Summative assessment
One Quizz per module
20% each for the final grade (?)

Training Schedule

1st cohort

Start date: 14 November 2026

End date: 31 December 2026

Registration deadline: 13 November 2026

2nd cohort

Start date: 15 January 2027

End date: 15 April 2027

Registration deadline: 3 January 2027

Language

English