Additive Manufacturing Component Testing Methods

Additive manufacturing (AM), or “three-dimensional printing” as it’s often called, is a thriving industry set to grow by more than 26% from 2021 through 2028.

AM component testing is an essential part of developing reliable parts.

Advancements in technology continue to drive that growth, and Innovative Test Solutions has identified a glaring gap in AM component testing methods: lack of effective ultrasonic non-destructive testing for optimal additive manufacturing quality control.

It’s critical across all industries but is particularly crucial in aerospace and transportation.

With this understanding in mind, ITS set out to develop AM component testing methods that can reliably catch defects, grow defect databases, and support sustainable growth throughout the AM industry.

The Need for Non-Destructive Testing in Additive Manufacturing Quality Control

Existing AM testing methods, such as tensile, fatigue, creep and stress rupture, in addition to crack and fracture testing offer data and insights that can be helpful. However, these traditional AM component testing methods also have serious limitations.

Companies have recently explored non-destructive testing alternatives like computed tomography, radiography, and Eddy current tools. All methods have proven to be time-consuming and expensive, with some tools only appropriate for small and simple AM parts or surface-level testing.

Safety, particularly in the transportation and aerospace industries, takes a front seat in additive manufacturing quality control.

Understanding the potential for defects in any part is critical, and industries also have a genuine need for timely, cost-effective testing methods to assess parts’ internal structures accurately.

Holographic Non-Destructive & Vibration Testing as a New AM Component Testing Method

What if there was a way to create a nearly defect-free AM component that matches the model as closely as possible?

With the combination of vibration testing and holographic non-destructive testing, that golden model of the perfect part may be within reach.

Vibration testing isn’t new, it has been an integral part of the aerospace industry, which used it to assess components’ fatigue levels and to develop S-N curves. Vibration testing focuses on the number of cycles it takes for components to develop defects at a given energy level.

By combining it with holography, each part’s modal signature can be identified and used to evaluate the component’s structure.

Modal assurance criterion (MAC) can then help determine variations between parts. Those differences can be mapped and used as data points to compare nearly defect-free modal models with AM produced parts to generate each part’s MAC.

How it Works

ITS has discovered the value of applying the same method to manufactured parts or objects and creating golden modal models. Those models can then run comparisons to assess additively manufactured parts, generate their MACs, screen for defects, and evaluate quality.

Ultimately, the method has the potential to facilitate defect screening that is effective and non-destructive. Any identified defects can be explored further to create a database housing insight into the effects of various defect types on modal data. MACs could be used to indicate defect probability and provide a simple go/no-go result.

Benefits of the ITS Component Testing Method

Not only is this AM component testing method cost-effective, it also offers the ability to qualify parts at a fast rate. With use, a defect database that relates defects to part quality will continuously grow, allowing greater understanding of defect causes and effects over time.

Ultimately, component testing method from ITS has the potential to help produce faster, higher-quality AM parts.

Additionally, the data conferred by its use could decrease scrap rates and increase tolerance by providing a comprehensive understanding of defects, part properties, and part life. In this way, ITS’ AM component testing method could provide additional cost savings.

Discover the Custom Solutions ITS Provides

The AM component testing tool is just the latest innovation in a long line of custom solutions provided by ITS since its founding in 2004.

ITS is a leader in design and machining services with a stellar reputation in the field. Engineers work closely with clients to build effective, customized testing solutions.

From additive manufacturing to aerospace transportation industries, the ITS team provides comprehensive testing, research, and solutions. The goal is always to help clients meet and exceed their goals.