Improving Additive Manufacturing Quality
Sigma Labs Inc. is a leading provider of in process quality assurance (IPQA®) software to the additive manufacturing (AM) industry under the PrintRite3D® brand. Founded in Santa Fe, New Mexico, in 2010 and employing 27 skilled workers the company specializes in the development and commercialization of real-time monitoring solutions for 3D metal advanced manufacturing technologies enabling cost-savings and production efficiencies. As an industrial leader in their field Sigma Labs teamed up with DMG MORI, a leading full-liner of additive manufacturing technologies for metal components, to enhance quality control in the additive manufacturing process.
Additive manufacturing plays a critical role in multiple advanced industries and its current and potential applications are extensive. From more simplistic uses such as small-scale component manufacturing to high-stakes applications in medical devices, aerospace, automotive, as well as oil and gas, the technology is a driving force in the innovation of the manufacturing industry. With increasing significance of additive manufacturing the requirements in terms of quality and productivity are rising, too. “In these industries, failure of the final product is simply not an option,” states Ron Fisher, Business Development at Sigma Labs. Even the most minor inconsistencies in small parts can create dire consequences for end users. “For example, a poorly made acetabular cup used in a hip arthroplasty could result in the catastrophic failure of the replacement and extreme pain and suffering for the patient.” In the manufacturing of parts for aerospace or automotive, the consequence of poor quality control could result in lives lost.
In-process quality assurance for Additive Manufacturing
“To enhance quality control and reduce waste, increase productivity and improve efficiency challenges, the AM industry requires In-Process Quality Assurance systems that compensate for in-build fluctuations,” explains Ron Fisher. Working on this issue Sigma Labs has found a reliable partner in DMG MORI. The machine tool manufacturer seeks to elevate and industrialize the AM process while simultaneously focusing on consistent quality and reliability in all parts produced. The company utilizes a full-circle strategy that begins with the design and programming process utilizing proprietary software. They horizontally integrate the additive process with the machining process using standardized interfaces and the integration of the digital process chain.
DMG MORI has been meticulous in its dedication to perfection in the QA process. However, the company wanted a QA solution that would allow the operator to have more control during the AM process, Ron Fisher remembers: “While post-process quality control is beneficial in catching errors before they go to end-users. That is really all it can do. Inspection is important but usually too late to address and prevent problems.” Additionally, post-process QA is time-consuming, expensive and in many cases destructive.
“DMG MORI sought an in-process QA tool that would allow their customers to adapt and overcome problems before the final product was complete, saving time and resources while continuing to uphold the company’s standards for helping its users manufacture reliable, safe parts,” says Ron Fisher.
That is why Sigma Labs and DMG MORI joined forces. The aim was to qualify Sigma’s inprocess quality assurance (IPQA®) software PrintRite3D® and begin preparing its AM machines factory supplied as “PrintRite3D Ready”. Specifically, a number of melt pool issues were identified and detected, including lack of fusion and keyhole anomalies using the TEP and TED metrics in conjunction with machine learning models to register and map post process CT data – helpful information for making in-process decisions that can eliminate problem parts before they start to affect other parts on the build plate.
Proven powder bed technology from DMG MORI
Looking at the hardware DMG MORI contributed their LASERTEC SLM series to the cooperation. It includes the LASERTEC 30 SLM 2nd Generation with its large installation space of 11.8 × 11.8 × 11.8 in and the LASERTEC 12 SLM, which sets new standards in precision thanks to its focus diameter of only 35 μm / 0.0014 in. In relation to this accuracy class, it has the largest installation space at 4.9 × 4.9 × 7.9 in. The latest highlight in the portfolio of the LASERTEC SLM series is the LASERTEC 30 DUAL SLM. With it, DMG MORI sets new standards in selective laser melting. Two powerful 600 W lasers, each with scan fields covering the entire build space, enable highly productive build rates. The software automatically recognizes which scan strategy is most efficient. Thus, the LASERTEC 30 DUAL SLM always works optimally and can be used flexibly depending on the order situation. Meanwhile, a focus diameter of 50 μm / 0.0018 μ in enables a precision that is unique in this machine class. A common feature of all LASERTEC SLM machines is the powder change by means of the rePLUG powder module. On the one hand, the closed powder circuit ensures the work safety mentioned at the beginning, and on the other hand, the powder can be changed easily within two hours with the help of the rePLUG powder modules.
Using PrintRite3D® on the LASERTEC SLM machines DMG MORI’s in-process monitoring was enhanced. The benefits resulted in faster product development, reduced trial and error and minimized waste as well as machine time. Sigma Lab’s innovative melt pool monitoring, additionally, was instrumental in achieving important QA goals. “We get direct rather than indirect on the part because of the rich data output,” explains Ron Fisher. This also allowed for advanced material development capabilities. “The DMG MORI and Sigma Labs’ PrintRite3D® integrated solution was created for exactly this purpose. It adds significant value to manufacturers through increased production yield of 3D metal manufactured parts, cuts postprocess quality inspection costs and reduces time to market. These are big factors in enabling true industrialization of metal AM.”
LASERTEC SLM
HIGH PRECISION, HIGH QUALITY IN POWDER BED PROCESS
HIGHLIGHTS
- Powder bed with 11.8 × 11.8 × 11.8 in. construction volume
- Best in class precision with 50 – 300 micrometer laser spot diameter
- Permanent filtration system with 3,000 hours filter life
- CELOS: Consistent software solution
- Open system: Individual adjustment of all parameters
SIGMA LABS INC. FACTS
- Founded in Santa Fe, New Mexico, in 2010
- Software company providing In-Process Quality Assurance solutions for the Additive Manufacturing industry
- Patented technology that detects and identifies defects, real-time, during the 3D printing process
Sigma Labs Inc.
3900 Paseo del Sol
Santa Fe, New Mexico USA 87507
www.sigmalabsinc.com
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