As Additive Manufacturing (AM) advances from prototyping to full-scale production, industries like aerospace,automotive, and medical demand rigorous validation and certification processes.Ensuring parts meet the highest quality standards is no longer optional—it’s essential.
The Challenge of Certification in AM
Unlike traditional manufacturing, where inspections such as Coordinate Measuring Machines (CMMs) and visual assessments are well-established, AM presents unique challenges. Layer-by-layer production requires real-time validation, yet many manufacturers still rely on post-build inspections like CT scanning and destructive testing. While effective, these methods are expensive, time-consuming, and impractical for scaling AM into mass production.
At Phase3D, we see a critical issue:reliance on post-inspections not only limits AM scalability but also results insignificant material waste. In aerospace alone, post-inspection can account for over 50% of total part costs. This approach is neither cost-effective nor sustainable for AM’s future.
In-Process Inspection: The Future of Certification
The ability to validate parts in-process is transforming AM. Moving beyond subjective monitoring tools that capture only a snapshot of the build, real-time, unit-based inspections provide calibrated,repeatable measurements for each layer of production.
This is where Fringe Inspection™ plays a crucial role. Using structured light projection and camera-based detection,Fringe Inspection™ captures three-dimensional data during the build process to create a certifiable digital twin. This enables manufacturers to identify powder and melt anomalies—such as recoater streaks, short feeds, and part protrusions—in real-time. More importantly, it allows for data-driven process control, ensuring that each part meets certification standards as it is being produced.
Born-Certified Parts: A New Standard in AM
Rather than simply detecting defects, AM must evolve to producing born-certified parts—components that meet stringent quality requirements from the moment they are built, reducing reliance on extensive post-processing.
Born-certified parts hold immense value in industries where safety and performance are paramount. Aerospace components,for example, must not only meet strict geometric tolerances but also ensure material integrity to endure extreme conditions. Real-time inspection removes the need for costly reworks months after the build, ensuring every part is fit for use immediately after production.
Real-World Adoption and Industry Impact
Leading organizations, including NASA and the U.S. Air Force, have already integrated Fringe Inspection™ into their AM workflows. By correlating real-time inspection data with CT scans, these industry leaders are demonstrating the immense value of in-process validation—leading to faster, more cost-efficient production.
For manufacturers seeking to scale AM production, in-process inspection is crucial. It enables:
- Faster feedback and reduced lead times
- Lower risk of part failure, and root cause analysis when parts do fail
- More efficient, cost-effective workflows
The Path Forward: Certification as an Industry Catalyst
As AM matures, widespread adoption of in-process inspection will be a key driver of industry growth. The ability to certify parts directly from the machine will not only cut costs but also open doors for new applications in high-performance industries.
At Phase3D, we are committed to advancing in-process inspection, helping manufacturers achieve excellence in every build. By enabling real-time validation, we’re ensuring that AM reaches its full potential as a scalable, high-quality manufacturing solution.
Take the first step toward revolutionizing your AM workflows. Learn more about how Fringe Inspection™ can drive efficiency, reduce costs, and ensure born-certified quality in your production. Contact us today to discover the future of in-process inspection.
