Advanced Manufacturing 1 (Grade 11)

by Matt Joiner

Advanced Manufacturing 1 is the first of four courses that make up the grades 11-14 Advanced Manufacturing Pathway. This concentrator-level course focuses on intermediate level concepts and techniques used to explore the various welding, manufacturing, and machining techniques used in career fields related to welding, fabrication, machining, and milling. Topics included are: Careers in Manufacturing, Career and Technical Student Organization (CTSO SkillsUSA) & Leadership, Industrial Safety, 2D Modeling, Measurement, CNC Cutting, Oxyfuel Welding & Cutting, Plasma Arc Cutting, Shield Metal Arc Welding, Gas Metal Arc Welding and Gas Tungsten Arc Welding. Topics are taught using a variety of instructional methods including: guest speakers, industry tours, student work-experience, text book, multimedia, teacher-led demonstration and lab practices. Upon completion of this course, students can obtain basic proficiencies in unit areas and obtain various industry certifications, based upon proficiency level and performance on final projects and assessments. Successful completion of this course leads into Advanced Manufacturing 2.

Program Information
Course Certification Elements
Course Standards
California's 2013 CTE Standards (32)
Course Competencies / Outcomes
  • Adjust machine feed and speed, change cutting tools, or adjust machine controls when automatic programming is faulty or if machines malfunction. Unit 2,5
  • Check to ensure that work pieces are properly lubricated and cooled during machine operation. Unit 2,5
  • Clean machines, tooling, or parts, using solvents or solutions and rags. Units 2,5, 6, 7, 8. 9,10
  • Confer with supervisors or programmers to resolve machine malfunctions or production errors or to obtain approval to continue production. Unit 2,5
  • Analyze engineering drawings, blueprints, specifications, sketches, work orders, and material safety data sheets to plan layout, assembly, and welding operations. Unit 4
  • Check grooves, angles, or gap allowances, using micrometers, calipers, and precision measuring instruments. Units 2,4, 5, 6, 7, 8. 9,10
  • Chip or grind off excess weld, slag, or spatter, using hand scrapers or power chippers, portable grinders, or arc-cutting equipment. Units 2,5,6,8
  • Clamp, hold, tack-weld, heat-bend, grind or bolt component parts to obtain required configurations and positions for welding. Units 2,6,8,9,10
  • Clean or degrease parts, using wire brushes, portable grinders, or chemical baths. Units 2, 5
  • Clean, lubricate, maintain, and adjust equipment to maintain efficient operation, using air hoses, cleaning fluids, and hand tools. Units 2, 3, 5, 6, 7, 8, 9, 10
  • Compute and record settings for new work, applying knowledge of metal properties, principles of welding, and shop mathematics. Units 2, 3, 5, 6, 7, 8, 9, 10
  • Calculate dimensions or tolerances, using instruments such as micrometers or vernier calipers. Units 2,4,5 
  • Check work pieces to ensure that they are properly lubricated or cooled. Unit 5
  • Confer with engineering, supervisory, or manufacturing personnel to exchange technical information. Unit 4
  • Align and clamp workpieces together, using rules, squares, or hand tools, or position items in fixtures, jigs, or vises. Units 3,5,6,7,8,9,10




Course Work Based Learning Activities

Field trips, Cooperative Vocational Experience (CVE), Community Classroom (CC), media instruction from industry sources, industry guest speakers.

Course Materials

William E Bowditch. Welding Technology Fundamentals 4th Edition

Larry Jeffus. Welding Principles and Applications 5th Edition

Welding, NCCER Level 1 4th Edition

Course Units (180 hour course)

Unit 1: Careers in Manufacturing

Unit Length (Hours):

40 Hours

Unit Description:

In this unit students will explore current trends in today’s Manufacturing careers. While manufacturing offers a variety of career areas, this pathway is designed for students to focus their research in the areas of: welding, fabrication, 2D modeling and machining. Students will perform guided, web-based, research on both local and more distant domestic Manufacturing companies/careers. Research will explore different companies, required employee qualifications, necessary education and experience, typical working conditions/job descriptions and salary/benefits for each company. Field trips to local manufacturers, as well as industry, trade school and post-secondary CTE guest speakers are integrated in this unit. Students will use this industry perspective  information as another form of obtaining current Manufacturing careers information.

Unit Competencies/ Outcomes

  • Students will obtain general knowledge of current local and distant manufacturing career opportunities
  • Students will be able to explain required education, experience  and any necessary industry certifications required for specific manufacturing careers
  • Students will be able to explain typical salary/benefits associated with each type of career
  • Students will begin to gain direction in post-secondary plans to pursue a career in manufacturing 

Unit Assessment

  • Technical, word-processed, research paper summarizing above-mentioned aspects of Manufacturing careers exploration.

Unit 2: CTSO's and Leadership

Unit Length (Hours):

20 Hours

Unit Description:

SkillsUSA is a partnership of students, teachers and industry working together to ensure America has a skilled workforce. It is a national nonprofit organization serving high school and college students who are preparing for careers in trade, technical and skilled service occupations. This unit focuses on aspects of student skill growth and leadership development through SkillsUSA. Students will have the opportunity to apply CTE skills taught in specific courses to real-world situations and SkillsUSA competitions at regional, state and national levels. Students will learn how to complete a resume, job application(s), cover letter and other relevant aspects of building a portfolio. Additionally, soft skills in the workplace will be emphasized within this unit. Topics including acceptable uses of cell phones and social media in the workplace will be addressed. Students will research and practice job interview skills and perform mock interviews with the pathway’s advisory/business partners. Students will also explore proper attire for both interview and daily work expectations in the manufacturing sector. 

Unit Competencies/ Outcomes

  • Demonstrate proficiency in Advanced Manufacturing technical content through participation in regional, state or national SkillsUSA Leadership Conference
  • Demonstrate knowledge of content from within the SkillsUSA PDP State-level test
  • Student will produce a resume, cover letter and practice job application(s)
  • Understand appropriate use of cell phones and potential negative effect of social media use as related to the workplace
  • Demonstrate proficiency in job interview and soft skills

Unit Assessment

  • Comprehensive Portfolio including: Resume, Cover letter, sample job application(s), samples of student’s technical work, documents demonstrating participation in skill development contests at Regional, State and/or National Levels of SkillsUSA 

Unit 3: Industrial Safety

Unit Length (Hours):

20 Hours

Unit Description:

This unit will focus on aspects of personal safety and clothing, fire safety, general machinery safety, proper ventilation, storing compressed gases, lifting techniques, hazardous obstacles, hand and power tools, designated welding and cutting areas, welding on containers, and general material handling techniques. Instructional methods used in this unit include textbook, teacher-led demonstrations, student labs and OSHA 10 certification training.

Unit Competencies/ Outcomes

  • Identify  common hazards found in welding
  • Explain and identify proper personal protection used in welding
  • Describe how to avoid welding fumes
  • Explain some of the causes of accidents
  • Explain safety techniques for storing and handling cylinders
  • Explain how to avoid electric shock when welding
  • Describe proper material handling methods 

Unit Assessment

  • OSHA 10 Safety Certification 
  • Successful completion of written safety test

Unit 4: 2D CAD Image Creation

Unit Length (Hours):

15 Hours

Unit Description:

In this unit, students will be given a 2D image from which they will create a 2D CAD file to be (later) cut on a CNC machine. Students will learn the required steps to take a digital image and then create a 2D outline of that image, using CAD software. Students will then perform appropriate software nesting procedures to prepare the file format for the next unit, where the file will be cut on a CNC machine. Once students have gained basic CAD software operational knowledge, CAD file creation and nesting processes, they will repeat the steps with a more complex image. This second image will build upon concepts and skills learned in the process of the first image creation.  Students will develop a deeper understanding of the file creation process through the second (more complex) file creation process. 

Unit Competencies/ Outcomes

  • Students will be able to read a tape to measure to 1/16” accuracy
  •  Students will be able to add and subtract fractional and decimal measurements
  •  Students will have basic operational drafting skills with current industry software (including, but not limited to: SolidWorks, AutoCAD or Adobe)
  •  Be able to effectively use CAD software functions including: mirror, copy, scale, line, arc and measurement tools
  •  Be able to explain to 2D file creation and software nesting processes 

Unit Assessment

  • Successful basic and intermediate level 2D CAD files (to be cut in the next unit)
  • Possible NIMS Measurement Certification 

Unit 5: CNC Cutting

Unit Length (Hours):

5 Hours

Unit Description:

In this unit, students will cut and finish a part on a Computer Numeric Control (CNC) cutting machine. In the previous unit (2D CAD Image Creation), students created a 2D CAD file from a determined 2D image and performed software nesting. Students will now transfer the nested part to the CNC cutting machine and follow procedures to cut a single part from nested file. Students will then perform finishing procedures on the single cut part. This process should include (but not limited to) removal of any slag or drop resulting from the cutting process, surface contamination removal, solvent preparation, paint, powder coat or other accepted method of part finishing. Students will repeat the described steps in this unit with the second, more complex CAD file that was created in the previous unit. This method of repeated practice will deepen students' understanding and technical skills of the processes in this unit.

Unit Competencies/ Outcomes

  • Select appropriate gauge sheet metal to perform cutting desired part from CAD file
  • Basic maintenance and troubleshoot of CNC machine software
  • Evaluate and change consumables/ maintenance parts associated with CNC machine
  • Upload a nested file and follow procedure to produce cut CNC part
  • Perform post-cut part clean up and metal preparation for finishing processes
  • Apply finishing process(es) to single cut part 

Unit Assessment

  • Produce cut parts from 2D CAD files
  • Perform finishing procedures on cut parts: slag/dross removal, part cleaning, metal preparation for paint, clear coat or powder coating 

Unit 6: Oxyfuel Welding and Cutting

Unit Length (Hours):

10 Hours

Unit Description:

This unit will address aspects of oxyfuel welding and cutting applications. Focus areas will include: general oxyfuel safety, cylinder storage and handling, assembling the torch kit, pressurizing the oxyfuel set up, safely checking for leaks, lighting/adjusting the flame and shutting down the torch kit. Students will perform oxyfuel gas cutting techniques, including preparing materials to cut, manual cutting (both freehand and guided) and operation of entry-level automated cutting machines. Students will perform various oxyfuel welding and materials joining techniques, including brazing. Welds will be performed in the flat, horizontal, vertical and overhead positions. 

Unit Competencies/ Outcomes

  • Identify and explain the use of oxyfuel cutting equipment
  • Set up oxyfuel equipment.
  • Light and adjust an oxyfuel welding and cutting torch
  • Properly shut down oxyfuel  equipment
  • Safely change oxyfuel cylinders
  • Preform oxyfuel cutting practices: Straight line, square shapes, piercing, slot, bevel and wash
  • Operate a motorized, portable oxyfuel gas cutting machine.
  • Perform satisfactory common weld joint configuration in in the flat (1F), horizontal (2F), vertical (3F) and overhead (4F) positions

Unit Assessment

  • Demonstrate proficiency in setup, operation and maintenance of oxyfuel equipment
  • Demonstrate proficiency in oxyfuel welding and cutting practices
  • Progress toward completion of NCCER Level 1 Certification 

Unit 7: Plasma Arc Cutting

Unit Length (Hours):

5 Hours

Unit Description:

This unit will address aspects of Plasma Arc Cutting (PAC) applications. Focus areas  include: Plasma Arc Cutting equipment, supplies, assembly, required personal protective equipment and related safety. Students will perform preparation to cut materials, plasma arc cutting, plasma arc gouging and hole piercing. Students will further explore the PAC process using various material thicknesses, including sheet metal and plate. Cut quality, kerf, dross and other aspects of the cut area will be examined for quality. Students will cut both ferrous and non-ferrous materials to gain a deeper knowledge of cutting principles. 

Unit Competencies/ Outcomes

  • Be able to explain safety and the plasma arc cutting process
  • Identify plasma arc cutting equipment
  • Prepare and set up plasma arc cutting equipment
  • Demonstrate proficient use of plasma arc cutting equipment to make various types of cuts on ferrous and non-ferrous materials
  • Properly store equipment and clean the work area after use 

Unit Assessment

  • Demonstrate proficiency  and acceptable cut quality in PAC free-hand & guided cuts on a variety of ferrous and non-ferrous metals 

Unit 8: Shielded Metal Arc Welding

Unit Length (Hours):

25 Hours

Unit Description:

This unit will address aspects of the Shielding Metal Arc Welding (SMAW) process. Focus areas will include: preparing to weld, safety precautions, striking an arc, arc blow, performing a weld bead, welding positions, electrode selection,  electrode manipulation techniques, understanding the molten puddle, post-weld cleaning and weld defects. Instructional methods used in this unit include textbook, multimedia, teacher-led demonstrations and student labs with an emphasis on NCCER Level 1 certification training and AWS certification training or progress toward AWS certifications.  Students will perform various SMAW materials joining techniques with appropriate filler material selections. Plate welds will be performed in the flat, horizontal, vertical and overhead positions. 

Unit Competencies/ Outcomes

  • Set up Shielded Metal Arc Welding (SMAW) equipment
  • Describe methods of striking an arc
  • Properly strike and maintain an arc
  • Describe causes of arc blow and methods to correct
  • Describe the relationship between joint fit up, proper amperage, travel speed and electrode manipulation technique
  • Make  satisfactory stringer and weave beads on plate material
  • Make groove and fillet welds on plate materials up to 1’ thick in the flat (1F), horizontal (2F), vertical (3F) and overhead (4F) positions

Unit Assessment

  • Demonstrate proficiency in setup, trouble shooting and operation of SMAW equipment
  • Demonstrate proficiency in SMAW welding process
  • Possible NCCER Level 1
  • Possible AWS Certification in SMAW process

Unit 9: Gas Metal Arc Welding

Unit Length (Hours):

20 Hours

Unit Description:

This unit will address aspects of the Gas Metal Arc Welding (GMAW) process. Focus areas will include preparing to weld, safety precautions, methods of metal transfer, welding positions, equipment parts identification, gun angle, gun manipulation techniques, understanding the molten puddle, shielding gases,  equipment set up and troubleshooting techniques. Instructional methods used in this unit include textbook, multimedia, teacher-led demonstrations and student labs with an emphasis on AWS certification training or progress toward AWS certifications . Students will perform various GMAW materials joining techniques in both the short-circuit and pulse transfer methods. Both sheet metal and plate welds will be performed in the flat, horizontal, vertical and overhead positions. 

Unit Competencies/ Outcomes

  • Describe the methods of metal transfer
  • Be able to name and describe the uses of key parts of the GMAW equipment
  • Explain the variables in the process and how they relate to weld quality
  • Be able to set up GMAW equipment
  • Set proper drive roll tension and describe steps for removing a bird’s nest
  • Describe the relationship between gun angle and position, stick out, proper voltage, wire speed, manipulation techniques, shielding gas selection and how these factors relate to weld quality
  • Make groove and fillet welds on sheet and plate materials in the flat (1F), horizontal (2F), vertical (3F) and overhead (4F) positions

Unit Assessment

  • Demonstrate proficiency in setup, trouble shooting and operation of GMAW equipment
  • Demonstrate proficiency in GMAW welding process
  • Possible AWS Certification in GMAW process

Unit 10: Gas Tungsten Arc Welding

Unit Length (Hours):

20 Hours

Unit Description:

This unit will address aspects of the Gas Tungsten Arc Welding (GTAW) process. Focus areas will include: preparing to weld, safety precautions, assembly of a GTAW welding unit, preparation of the electrode for GTAW process, proper adjustment of shielding gas flow rate, identification of electrode designation, polarity and amperage selection for the type of metal to be welded. Additional focuses address equipment set up and troubleshooting techniques. Instructional methods used in this unit include textbook, multimedia, teacher-led demonstrations and student labs with an emphasis on AWS certification training or progress toward AWS certifications. Students will perform various GTAW materials joining techniques in direct current and alternating current polarities when appropriate. Both sheet metal and plate welds will be performed in the flat, horizontal, vertical and overhead positions for ferrous and non-ferrous metals.

Unit Competencies/ Outcomes

  • Describe the cleaning and metal preparation required for GTAW process
  • Be able to name and describe the uses of key parts of the GTAW equipment
  • Explain the variables in the process and how they relate to weld quality
  • Be able to set up GTAW equipment
  • Identify proper electrode for specific welding task
  • Describe the relationship between machine set up, shielding gas selection and how each  factors relates to weld quality
  • Make acceptable groove and fillet welds on sheet and plate materials in the flat (1F), horizontal (2F), vertical (3F) and overhead (4F) positions on ferrous and non-ferrous metals

Unit Assessment

  • Demonstrate proficiency in setup, trouble shooting and operation of GTAW equipment
  • Demonstrate proficiency in GTAW welding process
  • Possible AWS Certification in GTAW process
Course Summative Assessment

The course summative assessment is a student portfolio summarizing the work performed within the course. The foundation of the student portfolio was developed in the CTSO and Leadership Unit early on in the course. This foundational portfolio should have contained a resume, cover letter, sample job application(s), samples of student’s technical work and documents demonstrating participation in skill development contests at Regional, State and/or National levels of SkillsUSA. In addition to these portfolio items developed early in the course, appropriate documents should be updated to reflect content proficiencies, awards, samples of technical work/welds, certifications and any other documents attained throughout the course. The format of the culminating portfolio should be comprehensive enough to display the students’ abilities and skill-sets; yet open ended enough meet the specific needs of the student and local employment opportunities.