QA & testing technology

Quality assurance in additive manufacturing

Quality management, testing technology, certificates

Quality assurance for 3D printing

Additive manufacturing is also a question of trust. In order to offer our customers optimum 3D printing quality at all times, we have developed a multi-stage quality management process for additive manufacturing. This begins with checking the print data and includes all the required documentation and traceability measures. With our quality assurance in 3D printing, we ensure that every component meets our high requirements and the specifications of our customers.

How we ensure 3D print quality

Process validation
We monitor and validate 3D printing quality using standardized test specimens and statistical process control (SPC) methods, among other things, to ensure the quality, consistency and repeatability of 3D printed components.
In-process quality monitoring
Special sensors and, if required, cameras monitor the printing process and stop it immediately if a deviation from defined target values is detected.
Post-process quality control
Our components are checked for compliance with specifications using various inspection procedures. These include visual inspections as well as measurements of geometry, surface roughness and component mechanics.
Traceability and documentation
The complete 100% traceability of components is ensured by documenting the printing process and materials. This is part of long-term quality assurance in the additive manufacturing of 3D printed parts. The documentation includes material certificates and print parameter protocols such as 3-1 certificates, QA test plans, declarations of conformity and test results.

Tested quality assurance additive manufacturing

Quality and quality assurance are very important to us in additive manufacturing. For this reason, we have consistently developed and expanded our quality assurance and quality management measures. This enables us to ensure that our 3D printing processes, data security and product quality meet the highest standards. Because we know how important quality assurance is for our customers, we regularly have our QA measures reviewed externally and through customer audits.

"Our 'gold standard' here is IATF 16949 for Tier 3 parts in the automotive industry. This level goes far beyond ISO 9001."

Testing technology for quality assurance in 3D printing

The highest quality requirements and the establishment of uniform standards are also becoming increasingly important for the additive manufacturing of 3D printed metal parts. That’s a good thing, because we set up our own test laboratory back in 2014 and have been setting standards for quality assurance in 3D printing for many years.

Continuous quality assurance
In our test laboratory, we monitor powder quality and system stability, carry out tensile tests, density tests and porosity measurements. We also test components using scanners and computer tomography. In this way, we ensure the consistent quality of the 3D printing process from the raw material to the finished component.

Comprehensively controlled production
FKM customers benefit from the safety and quality of optimally controlled additive manufacturing. In addition, we offer new services in our laboratory, such as the digitization of defective components and their rapid new production in one of our plastic or metal materials.

3D scanner for optical measurement

We use a special 3D scanner to check the shape and dimensions of 3D printed parts. This captures 3D coordinate points on the surface of the component during optical coordinate measurement (OCM). These are then converted into a 3D point cloud and used for quality control or further processing of the component.

Density measurement with density cube

A decisive factor for the quality and consistency of a 3D printed part is its density. Only if this meets the specifications can the required mechanical properties of the component be reliably maintained. For this reason, we regularly carry out density measurements. For this purpose, a test specimen, the so-called density cube, is built during the 3D printing process. Its density is then measured. We can use the measured values to detect errors in the print setting or material and correct them immediately.

Tensile test

In order to test the resistance of components to the effects of force, we carry out standardized tensile tests. This involves clamping 3D printed samples and pulling them apart in a controlled manner. The force-elongation curve obtained provides information about the mechanical properties of the sample and enables us to determine its strength, stiffness and elongation at break. It is also possible to determine how good the quality of the bonding layers in the 3D printed blank is. Depending on the result, we further optimize the 3D printing process or adjust the material used until the component has the required properties.

Particle measurement 3D printing powder

In addition to the perfectly coordinated process, the quality of an additively manufactured 3D printed component depends in particular on the 3D printing powder used. For this reason, we carry out special particle measurements in which we examine the particle size and particle quantity. We guarantee that only tested and approved material is used for component production.

Shore hardness measurement

To examine the hardness of 3D printed parts, we carry out Shore hardness measurements if required. We use this to determine the material's resistance to the penetration of a body of a certain shape under a defined spring force: the higher the Shore hardness value, the harder the material. We measure the Shore hardness with a special Shore hardness tester whose measuring pin is pressed onto the surface of the material. The result of this measurement is important for determining the suitability of a 3D printed component for a specific application.

Microscope

FKM uses a microscope to measure the surface quality of the printed part, such as roughness, scratches or unevenness. The surface data is used for quality control or to optimize the printing process.

Roughness measurement

Our roughness measuring device is equipped with a measuring arm that moves over the surface and measures the height of the surfaces at various points. The measured roughness depth is the vertical distance between the highest and lowest points on the surface.

FKM is your high-end 3D printing service provider

for ready-to-install parts made of plastics, filled polymers or metal.

From materials consulting and design optimization to joint project co-engineering, we are our customers’ experts and partners for tricky tasks. With our complete after-print service consisting of testing technology with IATF certification and a range of surface technology with various finishing processes, we have been offering 3D printing services as a complete solution for almost 30 years – from a single source, with a lot of understanding.