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You are employed as an apprentice machinist at an engineering firm producing a range of small prototype components, currently the company is using computer numerical control and computer aided manufacturing systems.

As part of your training within the company you have been asked to perform an investigation into additive manufacturing processes to better understand their benefits, the technology involved and typical applications, with a view to developing the use of additive manufacturing within the company.

Task 1

You have been asked to produce a report that investigates the technology and characteristics of additive manufacturing (AM), including sustainability and safe working practices, used in engineering.

To do this:

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.
Typical applications of the identified AM processes, including materials used; and
Factors relating to manufacturing activities using the identified AM processes, including sustainability, safety and capacity.

You then need to

Produce an accurate technical report that gives a balanced justification of how your two identified AM systems could benefit the manufacturing organisation, with reference to: a) the technology used and the characteristics of each process; b) sustainability; and, c) safe manufacturing procedures. Your report should include the following:

An investigation of how the identified AM system differ in terms of their ability to produce different components, the complexity they can achieve, and the types of surface finish different processes produce. Additionally, you should provide information about how a manufacturer achieves the desired consistency and accuracy of products/components and the operations performed during the processes. You should also consider the different machine’s footprint and speed of operation.
Information about the sustainability of the identified AM processes including recycling, energy use, waste material and the disposal of waste material.
Information about relevant safe working procedures, including use of guards and relevant H&S regulations, for example COSHH, and the Personal Protective Equipment at Work Regulations, and how these apply to the identified AM processes.
Information about the safety hazards associated with the identified AM processes, for example x-rays, ultraviolet rays, flammable powders, risk of explosions, handling materials and high temperatures


Checklist of evidence required		An accurate technical report including diagrams were applicable, that gives a balanced justification of the technology and characteristics of additive machining when operated safely and used sustainably
Criteria covered by this task:
Unit/Criteria reference	To achieve the criteria, you must show that you are able to:
45/A.D1	Justify, using language that is technically correct, the technology and characteristics of at least two additive processes used to manufacture components safely and sustainably
45/A.M1	Compare the technology and characteristics of at least two additive processes used to manufacture components safely and sustainability.
45/A.P1	Explain the technology and characteristics of at least two additive processes used to manufacture components safely and sustainably.
Sources of information to support you with this Assignment		Pearson BTEC National Engineering Student Book ISBN 978-1-292-14100-8
		3D Printing: Third Edition C Barnatt
		ISBN 978-1-539-65546-6
		Websites
		www.stratasys.com/
		www.renishaw.com/en/additive-manufacturing-systems– 15239

List of AM processes and their types:

Material extrusion – fused deposition modelling (FDM)

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.

You have been asked to produce a report that investigates the technology and characteristics of additive manufacturing (AM), including sustainability and safe working practices, used in engineering. To do this: You need to