Materials Expertise for Additive Manufacturing
For manufacturers, developers and qualification managers in additive manufacturing: powder characterization, process analysis and testing concepts – as the basis for reproducible quality and reliable approval procedures.
LPBF / SLM EBM Powder characterization Process qualification Series readiness DIN EN ISO/ASTM 52900 Approval supportCHALLENGE
Additive manufacturing can do a lot – but reproducible quality and approval readiness do not happen on their own.
- The powder batch fluctuates – mechanical properties vary from component to component, with no clear cause.
- The process runs in the lab – but how do you get from there to a reproducible, certified series?
- How much longer will the machine run reliably – and what do the standards say about it?
- Porosity, cracks, residual stresses or unexpected microstructures jeopardize component integrity.
Qualification project in planning or aiming for series readiness?
SERVICES
Three core services for the path from idea to qualified series
Powder Characterization & Raw Material Qualification
Analysis and qualification of metal powders and other raw materials as the basis for reproducible component quality.
- Particle size distribution and morphology
- Chemical composition (OES, EDX)
- Flowability, apparent density, tap density
- Moisture content and satellite powder analysis
- Powder recycling assessment (ageing behavior)
Process Analysis & Qualification for Series Readiness
Systematic analysis and optimization of additive manufacturing processes – from parameter identification to a stable, reproducible series.
- Process parameter analysis and optimization
- Porosity and defect assessment (CT, metallography)
- Residual stress analysis and heat treatment concepts
- Microstructure characterization and mechanical property determination
- Statistical process control and SPC concepts
Testing Concepts for Approvals & Certifications
Development of standard-compliant test and inspection concepts for approval procedures of manufacturing processes and components – as the interface to certification bodies.
- Preparation of qualification plans and test matrices
- Procedure and witness sample concepts
- Interface to notified bodies (TÜV, NADCAP, etc.)
- Support for industry-specific approvals (aerospace, medical, energy)
- Documentation for Design Approval Holder (DAH)
SUPPORTED PROCESSES
Our foundation
POWDER QUALITY – THE UNDERESTIMATED LEVER
Reproducible component quality starts with the raw material – not with the process parameters.
Sphericity, satellite powder and bimodal distributions directly affect the packing density in the powder bed and thus the porosity and surface quality of the component. We characterize and document comprehensively.
Even low oxide contents in the powder lead to inclusions, reduced toughness and failure under cyclic load. We perform comprehensive analysis according to ASTM B215 and accompanying standards.
Reused powder changes morphology and chemistry. We develop recycling strategies and define release limits for each powder batch – based on measurable characteristic values.
Batch and supplier comparisons based on defined characteristic value matrices protect against unplanned quality fluctuations in the series. We prepare specifications and release procedures.
FROM DEVELOPMENT TO SERIES
The qualification path in additive manufacturing – where we support you
Raw Material & Powder Qualification
Characterization and release of powder batches. Definition of incoming inspection specifications and recycling limits.
Process Development & Parameter Optimization
Systematic analysis of process parameters. Identification of the optimal process window for density, microstructure and mechanical properties.
Component Characterization & Defect Assessment
Comprehensive characterization of microstructure, density, residual stresses and mechanical properties. CT analysis for internal defects.
Qualification Plan & Testing Concept
Preparation of standard-compliant qualification plans and test matrices for notified bodies and certification authorities.
Series Release & Ongoing Quality Assurance
INDUSTRY APPLICATIONS
Additive manufacturing in demanding industries – specific requirements that we know
PROJECT REFERENCES (ANONYMIZED)
From practice – qualification projects we have accompanied
Complete powder and process qualification for a structural titanium component. Property determination, defect analysis and NADCAP documentation.
→ NADCAP accreditation successfully completed
Powder characterization, microstructure analysis and mechanical testing for an EBM-manufactured hip implant. Biocompatibility evidence according to ISO 10993.
→ MDR approval successfully prepared and submitted
Process optimization and creep testing for an LPBF-manufactured burner insert made of Inconel 625. SPC concept developed for series production.
→ Series release granted according to ASME requirements
WHY TECHNICAL CENTER
What AM manufacturers and developers value about our work
We are not tied to any machine platform – our assessments apply equally to LPBF, EBM, Binder Jetting and DED.
TYPICAL OCCASIONS
When developers and qualification managers contact us
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An AM component is to be used for the first time in a safety-relevant application – qualification evidence required
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Fluctuating mechanical properties in the series – cause unclear, whether powder, process or post-processing
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Supplier change for the powder – equivalence must be demonstrated
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NADCAP accreditation or approval by a notified body is pending – testing concept missing
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Porosity or defects in CT evaluation – assessment of component integrity and acceptance limits required
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Transition from prototype to series – reproducible quality must be statistically safeguarded
Acute failure case or ongoing inspection?
FREQUENTLY ASKED QUESTIONS
