Standardisation of additive manufacturing processes and relevant standards

Clear sets of rules and standards form the basis for additive manufacturing processes to be used in safety-critical areas. The standardisation of additive manufacturing processes creates uniform framework conditions for manufacturers, testers and users. Without these standards, broad industrial acceptance would hardly be possible.

The development of suitable sets of rules is a continuous process. New technologies and materials require constant adaptation of existing standards. At the same time, the standards must remain practicable and reflect everyday production.

Important international sets of rules and guidelines

International standardisation organisations are driving the standardisation of additive technologies forward. ISO and ASTM have combined their activities to create uniform standards worldwide. This cooperation prevents contradictory regulations in different regions.

The joint ISO/ASTM standards cover various areas. They define technical terms, specify testing methods and describe requirements for processes. Standard series on terminology and quality assurance are particularly important.

The fundamental standard works include:

These standards form the framework for a systematic approach. They enable companies to build up their processes in a structured way. In addition, they facilitate communication between different partners in the supply chain.

Further standardisation activities concern specific testing methods and material characteristic values. They define how mechanical properties must be determined. This produces comparable results regardless of the testing laboratory.

Requirements in various industry sectors

Every industry places its own requirements on the certification of additive manufacturing. Aviation is regarded as a pioneer with the strictest regulations. Here all process steps must be seamlessly documented and verified.

In medical technology, regulatory approval procedures apply. Products require a conformity assessment under medical device law. The requirements include biocompatibility, sterilisability and long-term stability of the components.

The automotive industry concentrates on series production requirements. Here reproducibility and cost efficiency are paramount. Standards must ensure that every component exhibits identical properties.

Pressure equipment construction is subject to the PED 2014/68/EU directive. For pressure equipment, a design examination by a notified body must often be carried out. These experts assess the particularities of additive design and manufacturing.

Special challenges with pressure equipment include:

The design examination takes place as early as the early development phase. Testers analyse the design using the finite element method. They assess whether the component withstands the mechanical loads.

After a successful design examination, the type examination follows. In this process, real prototypes are produced and tested. Only after a positive assessment of all evidence does the product receive approval.

Alignment and further development of existing specifications

The standardisation landscape is constantly evolving. Committees gather feedback from practice and integrate new findings. This exchange between users and standardisation institutions is important for practice-oriented standards.

Technological advances require regular revisions. New materials, improved machines and innovative processes must flow into the sets of rules. The speed of these adaptations is decisive for competitiveness.

International harmonisation remains a central goal. Differing national standards complicate global trade. That is why organisations are working to minimise regional differences and find common solutions.

Cooperation between different standardisation committees is intensifying. Industry associations contribute their specific requirements. Research institutions supply scientific foundations for new testing methods.

This dynamic process ensures that standards remain up to date. On the one hand they must safeguard proven practices. On the other hand they must not hinder innovation but should enable it and make it safe.

Quality assurance in 3D printing and process stability

Quality assurance in 3D printing presents companies with the challenge of controlling complex processes and keeping them stable. Unlike conventional manufacturing processes, every component is created layer by layer, with numerous influencing variables interacting. Only through consistent monitoring and control of these variables can consistent results be achieved.

Different printing technologies such as Metal 3D, FDM or SLS each bring their own requirements. The build volume of the machine, the base material used and technology-specific parameters determine which control measures are necessary. At the same time, the particularities of additive manufacturing must be taken into account: complex geometries, possible porosity and residual stresses in the material.

Keeping critical parameters in view

In powder bed-based metal processes, several variables decisively influence the manufacturing result. The laser power determines how much energy is introduced into the material. Scanning speed and layer thickness affect the penetration and bonding of the individual layers.

The hatch distance, that is the distance between the laser tracks, determines the density of the resulting component. The shielding gas atmosphere also plays an important role, as it prevents oxidation and protects the material quality. Even small deviations in these parameters can significantly change the mechanical properties.

Plastic processes require different priorities in monitoring. Temperature profiles must be precisely observed, from the melting point of the material to the cooling phase. The material flow must remain constant in order to ensure uniform layers.

Air conditioning of the build chamber prevents distortion and stress cracks during the printing process. Modern systems record these parameters continuously and document them for each individual layer. This data makes it possible to trace problems and implement improvements in a targeted manner.

Innovative monitoring technologies in use

In-situ monitoring refers to monitoring directly during the ongoing build process. Optical systems capture the quality of each powder layer before the laser fuses it. High-resolution cameras detect irregularities such as scratches in the powder bed or faulty coatings.

Thermographic monitoring analyses the melt pool in real time. Infrared cameras measure the temperature distribution and immediately detect deviations from the target value. Excessively high temperatures can lead to evaporation, too low temperatures prevent complete fusion.

Acoustic sensors complement the monitoring through noise analysis. Unusual sounds during coating or scanning indicate mechanical problems. Machine learning evaluates the collected data and recognises patterns that would not be discernible to human observers.

These modern approaches go far beyond mere logging. Intelligent systems can automatically initiate corrective measures when they detect deviations. The laser power is adjusted, scan patterns are optimised or the process is stopped in an emergency before costly errors arise.

Reliable repeatability through systematic measures

Process stability in 3D printing requires more than just technical monitoring. Regular machine calibration ensures that all components work precisely. Lasers, mirrors and coating systems must be checked and adjusted at defined intervals.

Material batch management prevents undesirable fluctuations caused by different raw materials. Every powder batch is documented and, if necessary, characterised. Critical applications even require batch-specific process adjustments in order to guarantee consistent results.

Standardised build preparation minimises human sources of error. Qualified process parameter sets are developed once, validated and then applied unchanged. Changes go through a controlled release process with corresponding documentation.

Environmental control covers temperature and humidity in the production area. Some materials react sensitively to fluctuations and absorb moisture. Maintenance plans define all necessary service work from filter cleaning to the replacement of wearing parts.

A holistic quality management system links technical controls with organisational regulations. Training enables employees to operate processes correctly and to recognise deviations. Checklists and work instructions standardise recurring activities and create transparency.

The combination of these measures creates the basis for long-term process stability. In this way, companies can raise quality assurance in 3D printing to a level that meets industrial requirements. Reproducible results arise from the interplay of technology, documentation and a systematic approach.