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Additive Manufacturing Essentials

Introduction

Additive Manufacturing EssentialsIntroduction
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A person crouches in an engine room with an array of large pipes, junctions, gaskets, and cables. The person reaches toward a component on one of the large conduits.
Figure 5.1 An engine specialist checks the fit of a 3D-printed valve onboard the littoral combat ship USS Indianapolis. The ship is 115 meters (378 feet long), with a typical crew of about 75 people, and carries several helicopters, surface vessels, and submersible vehicles. For AM parts to provide core engine functionality on such a massive platform, the crew must be certain they have been manufactured to exact specifications and pass multiple tests. (credit: U.S. Navy photo by Mass Communication Specialist 3rd Class Austin Collins on DVIDS, Public Domain)

Chapter Outline

5.1 Certification
5.2 Nondestructive Testing (NDT)

The topics of Certification and Qualification feature prominently in the future of Additive Manufacturing (AM). This is because AM is being developed in a wide range of industries to produce products with superior performance (weight, efficiency, cost, etc.), with the same reliability that conventional manufacturing has delivered for their customers. While the many regulatory bodies and certifying agencies have very detailed definitions unique to their field, in their simplest form the two terms are:

  • Certification – component meets design intent and is fit for service in a system
  • Qualification – the entire manufacturing process meets design intent, including the supplier, machine, and processing

Certification and qualification are not unique to highly regulated industries such as aerospace and medical. Because of the severe consequences of unanticipated failure, these industries have some of the most codified requirements. At the same time, not every industry, production process, or development team may refer to the terms separately or require every step in the processes. For example, if a part is being made as a model only, or is being developed as a proof of concept, it may require very specific (or limited) certification and qualification. In this chapter, we will discuss certification in terms of AM, and how it applies over the full range of applications from both safety-critical to those that are relatively mundane. Since part and system certification methods can be very industry-specific, it will be covered in general terms, along with common types of certifications (material, part, operator, etc.). We will cover qualification in the next chapter.

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