Anno Accademico 2023/2024

  • Docente: Alessandro Fortunato
  • Crediti formativi: 6
  • SSD: ING-IND/16
  • Lingua di insegnamento: Inglese
  • Moduli: Alessandro Fortunato (Modulo 1) Luca Raimondi (Modulo 2)
  • Modalità didattica: Convenzionale - Lezioni in presenza (Modulo 1) Convenzionale - Lezioni in presenza (Modulo 2)
  • Campus: Bologna
  • Corso: Laurea Magistrale in Advanced Automotive Engineering (cod. 9239)

Conoscenze e abilità da conseguire

The students will learn how to choose the best production processes for lightweight and advanced metal, polymer and composite material. They will learn how to prepare and optimize efficient manufacturing cycles, as well as how to ensure that those technologies are compatible with the planned requirements of final products. To emphasize the impact of manufacturing process parameters on product performance, case studies, laboratory and industry applications will be examined. For process development and optimization, software tools (such as FEM and CAE) will be introduced.


Metal materials

  • Introduction:
    • State of the art of products and processes (2h)
  • Fundamental on materials and their physical-chemical-mechanical properties (4h)
  • Copper and alloys
  • Aluminum and alloys
  • Soft magnetic materials
  • Hard magnetic materials
  • High-Strength-Steel and Ultra-High-Strength-Steel
  • Manufacturing processes (20h)
    • Stamping and hot stamping and tailored blanks solution
    • Thermal process manufacturing (cutting, joining, etc…)
    • Low thermal process manufacturing (sintering, diffusion bonding, )
    • Mechanical joining (clinching, riveting, etc…)
    • Additive process manufacturing (selective laser melting, direct energy deposition and wire arc additive manufacturing) to produce designed and lightweight materials.
    • Metal cutting for high performance materials
    • Electro-chemical-machining for lightweight production
    • Software for process simulation
  • Production systems in automotive industry (4h)
    • Industry 4.0 and Smart Manufacturing
    • Monitoring and process control (machine learning, deep learning and digital twin in automotive industry). Case study

    Composite materials

    -Basics of Structure Thermoplastic and Thermosetting polymers compared to Metals (2 hours);

    -Proprieties of polymer and reinforced polymers with powders, short and long fibers (2 hours);


  • injection molding,
  • extrusion,
  • blow molding,
  • stretch blow molding,
  • thermoforming,
  • press molding

description of the technologies, process parameters, case studies


-Properties of thermosetting resins

-Manufacturing of glass, carbon and aramidic fibers;

-From fibers to textiles: UD tapes and UD fabrics, multiaxial fabrics, classification of fabrics (styles, weight, proprieties);

-properties of pre-pregs,

-proprieties of cores and their application;

-Technologies for thermosetting composites:

  • Hand layup,
  • Vacuum Bagging,
  • Resin Transfer Molding (RTM) and variants (VARTM, VARI, HP-RTM, etc),
  • Pre-preg and Autoclave,
  • Pre-preg press Molding (PCM),
  • Short fiber press Molding (SMC),
  • Filament winding.

description of the technologies, process parameters, production rates, product proprieties, case studies.

Metodi didattici

Powerpoint presentations, slides and insights on the blackboard.

Exercises and discussion of industrial cases

Modalità di verifica e valutazione dell'apprendimento

Written test with open questions and quiz

Strumenti a supporto della didattica

Slides and textbook

Orario di ricevimento

Consulta il sito web di Alessandro Fortunato

Consulta il sito web di Luca Raimondi