Download Prospectus


Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

In this article we will look at some of the more advanced manufacturing processes which are widely used in today’s manufacturing industry:

Additive Manufacture

Additive manufacture (also known as additive layer manufacturing)  is a manufacturing technique where parts are created by depositing or adding layers of material on top of each other to produce the final part. This is different from machining where material is removed.
No doubt you will have heard of the term 3D printing. When we talk about 3D printing we are actually referring to a specific type of additive manufacturing, which starts with a 3D CAD model from which a physical part is produced by depositing, or printing, ‘layers’ of the material on top of each other.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

7 Categories of Additive Manufacturing

VAT Photopolymerisation

Vat polymerisation uses a vat of liquid photopolymer resin, out of which the model is constructed layer by layer.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Material jetting

Material jetting creates objects in a similar method to a two dimensional ink jet printer. Material is jetted onto a build platform using either a continuous or Drop on Demand (DOD) approach

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Binder Jetting

The binder jetting process uses two materials; a powder based material and a binder. The binder is usually in liquid form and the build material in powder form. A print head moves horizontally along the x and y axes of the machine and deposits alternating layers of the build material and the binding material.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Material Extrusion

Fuse deposition modelling  is a common material extrusion process and is trademarked by the company Stratasys.  Material is drawn through a nozzle, where it is heated and is then deposited layer by layer. The nozzle can move horizontally and a platform moves up and down vertically after each new layer is deposited.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Powder Bed Fusion

The Powder Bed Fusion process includes the following commonly used printing techniques: Direct metal laser sintering, Electron beam melting, Selective heat sintering, Selective laser melting and Selective laser sintering.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Sheet Lamination

Sheet lamination processes include ultrasonic additive manufacturing and laminated object manufacturing. The Ultrasonic Additive Manufacturing process uses sheets or ribbons of metal, which are bound together using ultrasonic welding.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Directed Energy Deposition

Directed Energy Deposition covers a range of terminology: ‘Laser engineered net shaping, directed light fabrication, direct metal deposition, 3D laser cladding’ It is a more complex printing process commonly used to repair or add additional material to existing components.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Powder Metallurgy Process

Powder metallurgy is a metal-forming process performed by heating compacted metal powders to just below their melting points. 

The process has been improved to such standards that it is now recognized as a superior way of producing high-quality parts for a variety of important applications. 

The process offers many advantages over other metal forming technologies such as forging and metal casting, advantages in material utilization, shape complexity, near-net-shape dimensional control, among others. These, in turn, contribute to sustainability, making powder metallurgy a recognized green technology.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

The below image is a selection of parts produced by Powder Metallurgy process including helical gear, stainless steel scissor blades, steel connecting rod for a V8 engine.

, Cutting-Edge Manufacturing: Exploring Advanced Techniques Shaping the Future

Interested in our engineering courses?

We have over 70 courses across all major engineering disciplines, including, mechanical, electrical and electronic, civil, aerospace, industrial, computer and general engineering. Visit our course catalogue for a complete list of fully accredited engineering programmes.

A small selection of short courses …

Diploma in Manufacturing

Diploma in Lean Manufacturing

Diploma in Material Science

Level 6 Courses

International Graduate Diploma in Mechanical Engineering  

Level 5 Courses

Higher International Diploma in Industrial Engineering

Higher International Diploma in Mechanical Engineering

Level 4 Courses

Higher International Certificate in Industrial Engineering

Higher International Certificate in Mechanical Engineering

Alternatively, you can view all our online engineering courses here.

Recent Posts

From Sparks to Strength: Top Welding Techniques You Should Know

From Sparks to Strength: Top Welding Techniques You Should Know Introduction From spark to structural bond—that’s the transformative power of welding. In the iLearn Engineering® article “From Sparks to Strength: Top Welding Techniques You Should Know,” readers are guided through essential welding methods—such as SMAW, MIG, TIG, and spot welding—each selected for strength, speed, or […]

Enhancing Materials: A Look into Surface Treatment Processes

Enhancing Materials: A Look into Surface Treatment Processes Introduction In manufacturing, selecting a material with the right bulk properties is only half the story. The performance of a component often hinges on what happens at its surface. The iLearn Engineering® article explores how various surface treatment processes—from coatings and plating, to shot peening, anodizing, and […]

How Material Removal Rate Affects Surface Quality and Production Speed

How Material Removal Rate Affects Surface Quality and Production Speed Introduction When machining components, one of the most critical—and often overlooked—factors is the material removal rate (MRR). It’s a common assumption that increasing MRR boosts productivity. However, as this iLearn Engineering article explains, this simple equation comes with important trade‑offs. Pushing MRR too high can […]