Design for Advanced Manufacturing: Aviation Lightweighting (2-Day Course)

In This Section

This 2-day course in partnership with Case Western Reserve University will provide a comprehensive and practical treatment of the major areas of advanced manufacturing for lightweight aircrafts.  Advanced lightweighting materials refer to all new, low-density materials that outperform conventional materials with superior mechanical properties such as strength, stiffness, toughness, hardness, durability and elasticity. These materials may also demonstrate novel properties including the ability to sense changes in the environment and respond accordingly. This two-day course will focus on advanced materials as applied to aviation lightweighting. In this course, the students will learn about ways to improve properties of advanced materials, manufacturing details and applications in various industries including aerospace and automotive.  Cutting edge trends in lightweighting will be discussed.

Learning Objectives 

• Understand aviation lightweighting technologies
• Understand practical uses of advanced manufacturing and materials
• Learn to diagnose and solve practical problems using additive manufacturing
• Learn the fundamentals of materials science and how to improve properties such as strength, stiffness, and ductility in a wide array of lightweight material options
• Understand aviation lightweighting AM technologies, trends and applications
• Understand the use of advanced materials databases (e.g., Granta) and the impact of key market drivers on the selection criteria for critical applications in the transportation industry
• Gain insights into practical problems in lightweighting and problem-solving skills through case study analysis

Who Should Attend

• Business Leadership
• Product Developers
• Engineering Managers
• Aerospace Engineers
• Structural Engineers
• Manufacturing Engineers
• Product Managers
• Materials Scientists
• Product Researchers and End Users

AIAA CEUs/PDHs are available for this course.

Curriculum Development Partners

Case Western Reserve University SLLP gratefully acknowledges their curriculum-development partners, including LIFT, ASM International, MAGNET and Granta Design.

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Case Western


Please contact Jason Cole if you have any questions about courses and workshops at AIAA forums.

• End-use markets that are driving use of lightweighting materials
• Introduce engineering advanced materials basics through the principles of materials science including advanced materials for lightweighting for increased efficiency - ferrous, nonferrous, others (e.g., polymers, ceramics, advanced composites)
• Review design methodologies commonly used throughout the transportation industry
• Demonstrate material selection tools and examples
• Discuss modern manufacturing techniques - powder metallurgy, casting, forging, rolling, extrusion, drawing, additive manufacturing
• Review the variables influencing materials performance - corrosion, materials degradation, fatigue, durability, maintainability, failure mechanisms, etc.
• Introduce lightweighting application examples including business case development
• Break up into working groups and solve problems in case study format

Course notes will be made available about one week prior to the course event. You will receive an email with detailed instructions on how to access your course notes. Since these notes will not be distributed on site, AIAA and your course instructor highly recommend that you bring your computer with the course notes already downloaded.

Dr. Michael L. Heil, Case Western Reserve University instructor is an independent aerospace and defense consultant with over 40 years’ experience in aerospace research, development, test, acquisition, and higher education. From 2007 to 2016, he served as President and CEO of the Ohio Aerospace Institute (OAI), a 60 person, $17M annual budget non-profit aerospace research and educational institute with offices in Cleveland and Dayton. Prior to joining OAI, Michael served as Director, Center for Space Studies and Research at the Air Force Institute of Technology. He retired from Air Force active duty in 2005 at the rank of Colonel after serving as Director of the Air Force Research Laboratory’s Propulsion Directorate with responsibilities for propulsion and power research at Wright-Patterson and Edwards Air Force Bases. A distinguished engineering graduate from the U.S. Air Force Academy, class of 1975, Michael earned a master’s degree in flight structures from Columbia University on a Guggenheim Fellowship and a doctorate in aerospace engineering from the Air Force Institute of Technology. He served as Commander, Phillips Laboratory; Commander, Arnold Engineering Development Center; and Commandant of the Air Force Institute of Technology. He has served in two Air Force acquisition centers, four defense laboratories, a test center, a major command staff, the Office of the Secretary of Defense, and the faculties of the Air Force Academy and Air Force Institute of Technology. He is a Fellow of the American Institute of Aeronautics and Astronautics.

Dr. Robert Bianco is an instructor in Siegal’s Lifelong Learning Program Continuing Professional Studies at Case Western Reserve University. Bob is a materials expert and technical lead for Swagelok’s Additive Manufacturing Program. Prior to joining Swagelok, Bob began his professional career in 1997 at Goodrich’s (now United Technologies Aerospace Systems) Materials and Simulation Technical Center where he held positions of increasing responsibility culminating as the Manager, Materials and Process R&D before his departure. He led a group of scientists and engineers to advance the state-of-the-art in materials and their processes for the aerospace industry. Prior to joining Goodrich, he was a Senior Engineer at Westinghouse’s Bettis Atomic Power Laboratory responsible for the development of material systems for advanced energy conversion applications. Bob earned a B.S., M.S., and Ph.D. in Metallurgical Engineering from The Ohio State University and an Engineering and Technology Management Certificate from Caltech’s Industrial Relations Center. Bob has authored 13 refereed journal articles, 50+ internal technical reports; 18 patents issued or filed, 40 invention records submitted; and 50+ presentations.