Quality and reliability

10.7.2023

Quality and reliability are key aspects in the production of 3D printed products, especially in applications where product failure can have serious consequences, such as healthcare, aerospace, or automotive.

Although 3D printing technology offers many advantages, ensuring consistent quality and reliability of printed parts remains a significant challenge. The following is an overview of the main issues and solutions.

1. Factors affecting quality

Materials:
Material diversity: The quality of the resulting products depends on the properties of the materials used (e.g. polymers, metals, composites).
Homogeneity: Variability in material quality can lead to differences in the mechanical and physical properties of printed parts.
Degradation: Some materials (e.g. plastics) can lose quality due to humidity or temperature.
Printing process:
Printer resolution: Low resolution can cause errors in detail.
Temperature control: Inconsistent temperatures during printing can lead to warping or weak bonds between layers.
Part orientation: The direction in which a part is printed affects its strength and mechanical properties.

2. Reliability Challenges

Layered Structure:
The mechanical properties of parts printed in layers are often weaker compared to traditional manufacturing methods (e.g., casting or machining).
Issues with delamination or cracking between layers can occur.
Complex Geometry:
3D printing allows for the creation of complex shapes, but these structures can contain hidden defects such as voids or inconsistent density.
Repeatability:
Printed parts from different printers, or even from the same printer, can exhibit differences due to changes in settings, materials, or environment (e.g., humidity).

3. Critical Applications and Requirements

Healthcare:
Implants, prostheses, or surgical instruments must meet stringent standards for biocompatibility, sterility, and mechanical durability.
Ensuring consistency in custom manufacturing is essential.
Aerospace:
Components must be high strength, low weight, and resistant to extreme temperatures and pressures.
Even a small error can lead to the failure of the entire system.
Automotive industry:
Critical parts, such as engine components or safety features, must be reliable and able to withstand repeated stress.

4. Solutions to improve quality and reliability

Process standardization

Implementing uniform procedures for preparing print files, selecting materials, and calibrating printers.
Using standards such as ISO/ASTM 52900 for additive manufacturing, which define key parameters and processes.

Advanced monitoring and control

Real-time print monitoring:
Cameras and sensors can monitor every step of the printing process, identify errors, and allow immediate correction.
For example, temperature sensors monitor the uniformity of material heating.
NDT (Non-Destructive Testing):
Using methods such as ultrasound, X-ray, or thermography to detect hidden defects without damaging the part.
Automated quality control:
Integrating artificial intelligence to analyze print data and predict potential problems.

Material Optimization

Development of new materials that have better mechanical properties, resistance to degradation and consistency.
Use of certified materials from verified suppliers.

Postprocessing

Heat treatment: Improving mechanical properties, removing stress and increasing cohesion between layers.
Surface treatment: Grinding, polishing or applying protective layers ensures the aesthetic and functional quality of the parts.

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