Reduce qualification risk with a validated Titanium additive manufacturing process designed for critical applications.
Faster Certification Starts with a More Capable Process
For aerospace, defense, medical, and other highly regulated industries, the true challenge of additive manufacturing isn't printing the part, it's about proving consistent quality, repeatability, and compliance. 3D Systems' latest Titanium Process Capability study demonstrates how our Direct Metal Printing (DMP) technology and LaserForm® Ti Gr23 (A) material provide the robust process control and statistical evidence manufacturers need to streamline validation and accelerate qualification of critical titanium components. Why It Matters Certification and validation programs require objective evidence that a manufacturing process consistently delivers parts that meet specification. This white paper shows that 3D Systems' DMP process was developed with this requirement in mind, combining tightly controlled machine architecture, rigorous process characterization, material traceability, and proven process capability. Key Advantages for Qualification Programs ✅ Built for Repeatability 3D Systems' DMP platforms utilize a vacuum-based chamber architecture and exceptional inert atmosphere control to minimize oxygen and moisture exposure. This helps maintain powder chemistry and ensures consistent mechanical properties from build to build. ✅ Stable Material Properties Across the Process Window A comprehensive Design of Experiments (DoE) study evaluated critical process variables including laser power, feed rate, argon flow, and build size. Results showed no practical significant impact on critical quality attributes when operating within the validated process window, evidence of a highly robust manufacturing process. ✅ Supports ASTM-Aligned Qualification Approaches The qualification methodology follows a risk-based framework aligned with ASTM F3434, including process validation, equipment validation, and product validation. Manufacturers can leverage existing material databases and machine capability studies to reduce qualification effort and avoid redundant testing. ✅ Exceptional Mechanical Capability Testing of Ti6Al4V Grade 23 components demonstrated process capability exceeding six-sigma performance for key mechanical properties, including yield strength, ultimate tensile strength, elongation, and reduction of area. The study reported zero out-of-spec mechanical results. ✅ Extended Powder Reuse with Full Traceability 3D Systems' continuous powder management strategy maintains tight control over powder chemistry and lot traceability. Analysis indicated powder oxygen levels remained within specification throughout reuse cycles, supporting both production efficiency and compliance requirements. Enabling Faster Time-to-Market The combination of proven process capability, controlled titanium powder management, validated equipment performance, and a decade-plus history of manufacturing critical applications helps reduce risk during qualification and certification activities. The result is greater confidence in part approval and a faster path from design to production. |
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