Ari Pikkarainen ACTA UNIVERSITATIS LAPPEENRANTAENSIS 969 LAPPEENRANTAENSIS UNIVERSITATIS ACTA ADDITIVE MANUFACTURING FOR MECHANICAL MECHANICAL FOR ADDITIVE MANUFACTURING DEVELOPMENT OF LEARNING METHODOLOGY OF OF LEARNING METHODOLOGY DEVELOPMENT ENGINEERING STUDENTS IN HIGHER EDUCATION 969 DEVELOPMENT OF LEARNING METHODOLOGY OF ADDITIVE MANUFACTURING FOR MECHANICAL Ari Pikkarainen ENGINEERING STUDENTS IN HIGHER EDUCATION Ari Pikkarainen DEVELOPMENT OF LEARNING METHODOLOGY OF ADDITIVE MANUFACTURING FOR MECHANICAL ENGINEERING STUDENTS IN HIGHER EDUCATION Dissertation for the degree of Doctor of Science (Technology) to be presented with due permission for public examination and criticism in the Auditorium 1316 at Lappeenranta-Lahti University of Technology LUT, Lappeenranta, Finland on the 7th of July, 2021, at noon. Acta Universitatis Lappeenrantaensis 969 Supervisors Professor Heidi Piili LUT School of Energy Systems Lappeenranta-Lahti University of Technology LUT Finland Professor Antti Salminen Department of Mechanical and Materials Engineering University of Turku Finland Reviewers Industry professor Iñigo Flores Ituarte Department of Digital Manufacturing University of Tampere Finland Program director DI Dr. Maximilian Lackner, MBA Innovation and Technology Management, International Business and Engineering University of Applied Sciences FH Technikum Wien Austria Opponent Program director DI Dr. Maximilian Lackner, MBA Innovation and Technology Management, International Business and Engineering University of Applied Sciences FH Technikum Wien Austria ISBN 978-952-335-677-1 ISBN 978-952-335-678-8 (PDF) ISSN-L 1456-4491 ISSN 1456-4491 Lappeenranta-Lahti University of Technology LUT LUT University Press 2021 Abstract Ari Pikkarainen Development of learning methodology of additive manufacturing for mechanical engineering students in higher education Lappeenranta 2021 123 pages Acta Universitatis Lappeenrantaensis 969 Diss. Lappeenranta-Lahti University of Technology LUT ISBN 978-952-335-677-1, ISBN 978-952-335-678-8 (PDF), ISSN-L 1456-4491, ISSN 1456-4491 The main aim of this thesis was to research the learning of additive manufacturing (AM) and the impact of using multiple AM technologies as a form of learning. The goal was to develop a new methodology for learning additive manufacturing in universities and universities of applied sciences and improve the AM knowledge transfer from higher education institutions to companies and industrial actors. The research work was connected to the development of AM education and to the design of the Lapland UAS mechanical engineering degree program´s new AM laboratory. Additive manufacturing is a method where an object is manufactured layer by layer from 3D CAD data. Seven different AM technologies exist, from which three of the most used ones are polymer-based printing technologies: material extrusion, vat photopolymerization and powder bed fusion of polymers. AM is on the verge of becoming recognized as one of the basic manufacturing methods and in order to make this happen, a methodology for AM education must be developed. The speed of technological development in AM is faster than AM education development; educational units such as universities and universities of applied sciences need efficient and organized methods in order to produce AM professionals according to the requirements of work- life. This happens by organizing practical AM learning environments and implementing AM into the curricula of engineering degree programs. This positively impacts society through the employment of educated AM professionals. Through this, knowledge related to AM increases in companies as they are more aware of the possibilities to use AM in their operations. The identification of learning based on AM and its pedagogical development are important, since AM learning is inversely related to AM requirements, which are connected to the experience level of students. The basic nature of engineering must be connected to AM principles by identifying the need for pedagogical development. Traditional pedagogics need an updated perspective on the implementation of AM in engineering education. AM is a relatively new technology and traditional pedagogics are not fully suitable for its implementation. The model of technical pedagogics provides a tool for AM´s more efficient implementation into curriculum. The practical arrangement of AM education needs an occupationally safe and practical learning environment and a function model in order to implement the AM studies according to a curriculum. The fundamentals of learning are based on learning outcomes and by mapping the needs of work-life related to AM education; thus, the AM knowledge transfer from university to work-life should be efficient. To accomplish this, engineering students´ learning of AM must be investigated. The use of multiple technologies in AM education improves students´ learning and therefore increases their knowledge and skill level. Keywords: additive manufacturing, 3D printing, learning environment, pedagogy, curriculum, learning outcome, technical pedagogy, knowledge transfer, multiple technologies. Acknowledgements I have worked on this thesis during the years 2018 – 2021 while working as a senior lecturer at Lapland University of Applied Sciences in the mechanical engineering degree program. This thesis forms the highlight of my academic career as it gives me the opportunity to achieve the highest academic degree possible. The dream of becoming a D.Sc. started to brew in my mind some years ago after my M.Sc. studies. My motivation towards academic research grew as I was able to combine my profession as a teacher with the area of additive manufacturing. I want to thank Professor Heidi Piili for being my mentor and main motivator starting from my M.Sc. studies. Without your burning enthusiasm and the ability to motivate your students, I would not to be where I am now in my academic career. You showed me, what academic research actually is and also the funny side of it; research does not always have to be so serious. I would also like to express my gratitude to Manufacturing 4.0 (MFG4.0) project which provided me support and knowledge base for this thesis. I want to thank professor Antti Salminen for giving me the opportunity to start my D.Sc. studies and being an active supporter in my academic path. I have learnt a lot about academic writing from you as you were a co-writer on my research papers. I want to thank my reviewers industry professor Iñigo Flores Ituarte, D.Sc. (Tech.) (University of Tampere) and program director Maximilian Lackner, Ph.D. (University of Applied Sciences Technikum Wien) for reviewing this manuscript and offering comments and suggestions for improving this thesis. I am deeply thankful to Maximilian Lackner for being also the opponent in my dissertation. I am grateful to Lapland UAS for giving me the opportunity to connect my work to my D.Sc. studies and supporting me in my studies in so many ways that I cannot even start to describe. My work means so much to me and the possibility to connect my studies to my work means the world to me. These past three years have been the most difficult time of my life due to many reasons and this thesis has been my lifebelt in so many ways. This process showed me that despite the difficulties you have in your life, having a goal will keep you motivated and focused. The loved ones in my life (you know who you are) have supported me and encouraged me to go forward, no matter what life throws into my path. For that, I am eternally grateful to you. Forward, that is the only direction to go. Ari Pikkarainen June 2021 Kemi, Finland Contents Abstract Acknowledgements Contents List of publications 9 Nomenclature 11 1 Introduction 13 1.1 Background and motivation .................................................................... 13 1.2 Scope and objectives ............................................................................... 14 1.3 Research overview .................................................................................. 15 1.4 Thesis structure ........................................................................................ 16 1.5 Scientific contribution ............................................................................. 17 2 Theoretical background 19 2.1 Additive manufacturing ........................................................................... 19 2.2 Fundamentals of learning ........................................................................ 20 2.3 Learning additive manufacturing ............................................................ 28 2.4 Learning methods and concepts for AM education ................................. 30 2.5 Knowledge transfer ................................................................................. 36 3 Methodology 39 3.1 P1 methodology ....................................................................................... 39 3.2 P2 methodology ....................................................................................... 39 3.3 P3 methodology ....................................................................................... 40 3.4 P4 methodology ....................................................................................... 41 3.5 P5 methodology ....................................................................................... 43 4 Results 47 4.1 Publication I ............................................................................................ 47 4.1.1 Objective