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Additive Manufacturing

Definición

layer-based manufacturing processes with specific CT requirements for non-destructive quality control

Sinónimos:
3D PrintingAMSLMSLSLPBFFDM

What is Additive Manufacturing?

Additive manufacturing covers layer-based production processes such as laser powder bed fusion (LPBF/SLM), selective laser sintering (SLS) or fused deposition modelling (FDM). CT inspection is particularly valuable here because complex internal structures (lattices, cooling channels, cavities) are inaccessible to conventional methods. At the same time, layer-wise build-up produces characteristic defect types that require a specific inspection strategy.

Scientific background

Typical defects in additively manufactured parts arise from melt-track interruptions (lack of fusion), gas porosity from trapped shielding gases, thermally induced cracks and inter-layer delamination. CT enables complete 3D visualisation of these defects. Characterisation follows the principles of porosity analysis (size, distribution, sphericity).

Relevant key metrics

  • Critical defect size depends on component load and relevant material standards (e.g. ASTM E2533 for aerospace).
  • Typical detectable pore diameters: ≥ 50 µm with micro-CT systems.
  • Layer distortion and dimensional accuracy (nominal/actual comparison) can also be quantified via CT.

Standards and thresholds

  • Standards: ISO/ASTM 52900 (AM fundamentals), VDI 3405 (laser powder bed fusion), ASTM E2533 (NDT for AM parts), DIN SPEC 17071 (AM quality assurance).
  • Typical thresholds: Depends on application; safety-relevant aerospace parts sometimes require zero-defect criteria for defects > 200 µm. For general applications, ≥ 1 % porosity is often a rejection criterion.
  • Validity: Inspection strategy and acceptance criteria must be defined per component and material.

Application in industrial practice

  • Release of safety-relevant AM parts in aerospace (first article inspection).
  • Process monitoring and parameter optimisation during series introduction.
  • Complete internal and external 3D dimensioning of complex topology-optimised structures.

Sources and reference date

  • ISO/ASTM 52900:2021.
  • VDI 3405 Parts 2.1 and 3 (laser powder bed fusion).
  • ASTM E2533-17.
  • DIN SPEC 17071:2019.
  • Reference date: March 2026.

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