{"id":624,"date":"2020-10-09T07:26:59","date_gmt":"2020-10-09T07:26:59","guid":{"rendered":"https:\/\/www.bk-werkstofftechnik.com\/en\/?p=624"},"modified":"2020-10-09T08:11:39","modified_gmt":"2020-10-09T08:11:39","slug":"3d-printed-parts-testing-support-every-step-of-the-way","status":"publish","type":"post","link":"https:\/\/www.bk-werkstofftechnik.com\/de\/news\/3d-printed-parts-testing-support-every-step-of-the-way\/","title":{"rendered":"","raw":""},"content":{"rendered":"","protected":false,"raw":""},"excerpt":{"rendered":"","protected":false,"raw":""},"author":4,"featured_media":636,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_en_post_content":"Additive manufacturing, commonly known as 3D printing, provides extraordinary flexibility, freeing designers from production related constraints and reducing innovation costs. Creativity can now be unleashed to focus on parts performance such as weight reduction, aerodynamics, functionality and safety.\r\n\r\n<!--more-->\r\n\r\nDid you know that currently <strong>3D-printed parts are more exhaustively tested than those produced by any other manufacturing method?<\/strong> Additive manufacturing implies <a title=\"exhaustive material testing\" href=\"https:\/\/www.appluslaboratories.com\/global\/en\/what-we-do\/services\/materials-testing\" target=\"_blank\" rel=\"noopener noreferrer\">exhaustive material testing<\/a> such as metallographic investigations, bearing, high cycle fatigue, fracture toughness and fatigue crack growth rate.\r\n\r\nWe are now going to go through the 3D printing validation process in detail, and how material testing is present in it every step of the way.\r\n\r\n<strong>Machine manufacturers<\/strong> need to make sure that their new 3D printers are able to meet customers\u2019 requirements, in terms of material properties. To do so, they need to test the materials they are going to use and obtain test data, which in turn will give them the chance to optimize their machines\u2019 parameters, to create material databases and guarantee customer satisfaction from the beginning.\r\n\r\n<img class=\"alignnone wp-image-627 size-full\" src=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/3D-printing-chart-1.2020-07-22-16-42-59.png\" alt=\"3D printing chart 1.2020-07-22-16-42-59\" width=\"1904\" height=\"777\" \/>\r\n\r\n<strong>Part manufacturers then install their 3D printers<\/strong> and begin conducting experiments to understand how different material inputs and machine configurations affect process outputs.\r\n\r\nSo, say for instance that you would like to buy a car\u2026 consider this a test drive, to see how it performs and if you are convinced!\r\n\r\n<img class=\"alignnone wp-image-628 size-full\" src=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/3D-printing-chart-2.2020-07-22-16-43-21.png\" alt=\"3D printing chart 2.2020-07-22-16-43-21\" width=\"1904\" height=\"777\" \/>\r\n\r\nThis \u201ctest drive\u201d is known as a <strong>Screening Test Program<\/strong> and it is at this point that part manufacturers get their samples (outputs) tested and receive their material properties so that they can determine whether the machine is performing according to their expectations and requirements.\r\n\r\nIn order to do so, they test several combinations of the following elements, with specimens being distributed in different batches: Machine used - Material Type - Powder Type - Parameter Set.\r\n\r\nMoving on and as seen in the above diagram, part manufacturers now enter the <strong>Process Qualification (PQ)<\/strong> phase. Its goal is to validate the production process and pursue repeatable and consistent results by conducting a high number of tests in order to avoid deviation and obtain stable isotropic material properties with the lowest possible spread.\r\n\r\n<img class=\"alignnone wp-image-629 size-full\" src=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/3D-printing-chart-3.2020-07-22-16-43-36.png\" alt=\"3D printing chart 3.2020-07-22-16-43-36\" width=\"1904\" height=\"777\" \/>\r\n\r\n3D printing methods may lead to components being manufactured with anisotropic mechanical properties. Therefore, specific tests are conducted with specimens printed with different build orientations (X \/ Y \/ Z) in order to avoid this from happening.\r\n\r\nAn interesting fact about testing 3D-printed samples is that they do not require to be cut and shaped as those from mechanical manufacturing processes. The specimens are printed out in near-final shape according to testing standards; however, they do need to be <strong>CNC-machined<\/strong> <strong>and surface treated<\/strong> with mechanical, chemical or galvanic processes in order to be individually tested and detached from the stock piece (blank or workpiece) they are provided on. Additionally, heat treatment processes are applied to reduce porosity and to generate reliable isotropic material properties.\r\n<p align=\"center\"><img class=\"alignnone wp-image-631\" src=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/Near-final-shape-printed-specimens.2020-07-17-12-56-08.jpg\" alt=\"Near-final-shape printed specimens.2020-07-17-12-56-08\" width=\"340\" height=\"386\" \/><\/p>\r\n<p align=\"center\"><em>Near-final-shape printed specimens<\/em><\/p>\r\nSignificant changes in the part design or dimensions, like wall thickness and printing orientation, can have an influence on materials\u2019 properties and make additional testing mandatory.\r\n\r\nAs soon as the desired results have been obtained with minimal or no deviation at all, part manufacturers enter the <strong>First Part Qualification (FPQ)<\/strong> phase.\r\n\r\n<img class=\"alignnone wp-image-630 size-full\" src=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/3D-printing-chart-4.2020-07-22-16-43-52.png\" alt=\"3D printing chart 4.2020-07-22-16-43-52\" width=\"1904\" height=\"788\" \/>\r\n\r\nThey will now begin designing and printing real parts. The objective is to guarantee that the previously identified material properties from the samples have been transferred to the parts.\u00a0Samples extracted from the part itself (\u201ccut-up parts\u201d) as well as individual samples from the same batch will need to be tested for this to be successfully verified.\r\n\r\nFor example, a typical First Part Qualification phase for aerospace parts includes mechanical tests such as tensile testing, fatigue testing and fracture-toughness tests.\r\n\r\nAfter exhaustive quantitative and qualitative testing, part manufacturers reach the <strong>Serial Production<\/strong> phase.\r\n\r\n<img class=\"alignnone wp-image-632 size-full\" src=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/Tabla-5.2020-07-17-12-25-26.png\" alt=\"Tabla 5.2020-07-17-12-25-26\" width=\"1905\" height=\"788\" \/>\r\n\r\nAt this point, quality control becomes essential, as part manufacturers need to guarantee the stability of the printing process. Quality control tests performed on the parts frequently include a visual inspection, dimensional control and NDT (such as digital radiography and surface crack inspections). A low amount of samples will need to be printed alongside them in each batch for further testing and will be subject to mechanical tests (such as tensile, hardness) and analytical tests (such as microscopic sections).\r\n\r\nFurthermore, part manufacturers will need to perform machine maintenance and revalidate their qualification processes on a regular basis.\r\n\r\nHere at Applus+, <a href=\"https:\/\/www.appluslaboratories.com\/global\/en\/what-we-do\/industries\/aerospace\" target=\"_blank\" rel=\"noopener noreferrer\">we have extensive experience in the Aerospace &amp; Defense sector<\/a><strong> and understand the challenges that come with 3D printing processes<\/strong>. We have developed a <a href=\"https:\/\/www.appluslaboratories.com\/global\/en\/what-we-do\/services\/materials-testing\" target=\"_blank\" rel=\"noopener noreferrer\">range of testing services to support the entire value chain of the additive manufacturing process<\/a>.\r\n\r\nWe deliver detailed test results to our customers, including a <strong>benchmark study<\/strong> contrasting actual vs ideal test data outputs (if facilitated) and also provide <strong>technical assistance<\/strong> for customers new to the 3D printing world that would like to get started and don\u2019t know what tests they can\/should carry out during each phase of the value chain.\r\n\r\nWould you like more information on our 3D printing testing services or is there something specific you would like assistance with?\r\n\r\nGet in touch with one of our experts and tell us all about it!","_en_post_name":"3d-printed-parts-testing-support-every-step-of-the-way","_en_post_excerpt":"Additive manufacturing, commonly known as 3D printing, provides extraordinary flexibility, freeing designers from production related constraints and reducing innovation costs. Creativity can now be unleashed to focus on parts performance such as weight reduction, aerodynamics, functionality and safety.","_en_post_title":"3D printed parts testing: support every step of the way","_de_post_content":"","_de_post_name":"3d-printed-parts-testing-support-every-step-of-the-way","_de_post_excerpt":"","_de_post_title":"","edit_language":"de","footnotes":""},"categories":[4],"tags":[],"class_list":["post-624","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-news"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.6 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>3D printed parts testing: support every step of the way - Applus+ BKW, Werkstoffpr\u00fcfung auf hohem Niveau<\/title>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/www.appluslaboratories.com\/global\/en\/news\/3d-printed-parts-testing:-support-every-step-of-the-way\" \/>\n<meta property=\"og:locale\" content=\"de_DE\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"3D printed parts testing: support every step of the way - Applus+ BKW, Werkstoffpr\u00fcfung auf hohem Niveau\" \/>\n<meta property=\"og:description\" content=\"Additive manufacturing, commonly known as 3D printing, provides extraordinary flexibility, freeing designers from production related constraints and reducing innovation costs. Creativity can now be unleashed to focus on parts performance such as weight reduction, aerodynamics, functionality and safety.\" \/>\n<meta property=\"og:url\" content=\"https:\/\/www.appluslaboratories.com\/global\/en\/news\/3d-printed-parts-testing:-support-every-step-of-the-way\" \/>\n<meta property=\"og:site_name\" content=\"Applus+ BKW, Werkstoffpr\u00fcfung auf hohem Niveau\" \/>\n<meta property=\"article:published_time\" content=\"2020-10-09T07:26:59+00:00\" \/>\n<meta property=\"article:modified_time\" content=\"2020-10-09T08:11:39+00:00\" \/>\n<meta property=\"og:image\" content=\"https:\/\/www.bk-werkstofftechnik.com\/wp-content\/uploads\/Zugversuch-Querformat.jpg\" \/>\n\t<meta property=\"og:image:width\" content=\"954\" \/>\n\t<meta property=\"og:image:height\" content=\"637\" \/>\n\t<meta property=\"og:image:type\" content=\"image\/jpeg\" \/>\n<meta name=\"author\" content=\"MarketingLabs\" \/>\n<meta name=\"twitter:card\" content=\"summary_large_image\" \/>\n<script type=\"application\/ld+json\" class=\"yoast-schema-graph\">{\"@context\":\"https:\\\/\\\/schema.org\",\"@graph\":[{\"@type\":\"Article\",\"@id\":\"https:\\\/\\\/www.appluslaboratories.com\\\/global\\\/en\\\/news\\\/3d-printed-parts-testing%3a-support-every-step-of-the-way#article\",\"isPartOf\":{\"@id\":\"https:\\\/\\\/www.bk-werkstofftechnik.com\\\/en\\\/news\\\/3d-printed-parts-testing-support-every-step-of-the-way\\\/\"},\"author\":{\"name\":\"MarketingLabs\",\"@id\":\"https:\\\/\\\/www.bk-werkstofftechnik.com\\\/en\\\/#\\\/schema\\\/person\\\/4a6abd6a13458f77b9b70c84694b8d3e\"},\"headline\":\"3D printed parts testing: support every step of the way\",\"datePublished\":\"2020-10-09T07:26:59+00:00\",\"dateModified\":\"2020-10-09T08:11:39+00:00\",\"mainEntityOfPage\":{\"@id\":\"https:\\\/\\\/www.bk-werkstofftechnik.com\\\/en\\\/news\\\/3d-printed-parts-testing-support-every-step-of-the-way\\\/\"},\"wordCount\":861,\"publisher\":{\"@id\":\"https:\\\/\\\/www.bk-werkstofftechnik.com\\\/en\\\/#organization\"},\"image\":{\"@id\":\"https:\\\/\\\/www.appluslaboratories.com\\\/global\\\/en\\\/news\\\/3d-printed-parts-testing%3a-support-every-step-of-the-way#primaryimage\"},\"thumbnailUrl\":\"https:\\\/\\\/www.bk-werkstofftechnik.com\\\/wp-content\\\/uploads\\\/Zugversuch-Querformat.jpg\",\"articleSection\":[\"Neuigkeiten\"],\"inLanguage\":\"de\"},{\"@type\":\"WebPage\",\"@id\":\"https:\\\/\\\/www.bk-werkstofftechnik.com\\\/en\\\/news\\\/3d-printed-parts-testing-support-every-step-of-the-way\\\/\",\"url\":\"https:\\\/\\\/www.appluslaboratories.com\\\/global\\\/en\\\/news\\\/3d-printed-parts-testing%3a-support-every-step-of-the-way\",\"name\":\"3D printed parts testing: support every step of the way - 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