A new automated in line quality control system based on non-destructive evaluation for additive manufacturing of net-shape parts from particulates

Additive manufacturing and 3D printing is a highly desirable and rapidly growing industry sector. During the manufacturing process microscopic cracks and porosity may form and be critical. These features may negatively affect the structural integrity of the components. Both Digital Radiography (DR) and Computed Tomography (CT) are highly sought after means of non-destructive evaluation (NDE) of net-shape parts from particulate materials in a smarter fashion. 3D CT imaging offers to detect local and bulk defects accurately in a reliable manner in-situ. Through this it will be possible to achieve an enhanced quality control operation towards ideally 100% coverage in manufacturing output, therefore, a more reliable production. This study hence details the seamless and safe integration of such a quality assurance approach in additive manufacturing. 3D CT image processing, Automated Defect Recognition (ADR) software and enclosure considerations are discussed. Added value for applications in major industry sectors (e.g. offshore, energy, security) is anticipated.