By: Noah Mostow
Last week, key leaders in the aviation industry gathered in Wichita, Kansas, for the annual joint Federal Aviation Administration (FAA) and European Union Aviation Safety Agency (EASA) Additive Manufacturing (AM)Workshop. Hosted by the National Institute for Aviation Research (NIAR), the event attracted attendees from original equipment manufacturers (OEMs),suppliers, and other experts from across the aerospace sector. For us at Phase3D,this was our first time attending, and one thing became immediately clear, AM is not just a buzzword in this sector, it is a crucial manufacturing resource and an increasingly valuable technology for aviation and aerospace companies. The industry is going to continue investing in and expanding its use of AM.
However, a significant challenge remains in AM aviation applications—AM technology, as it stands today, requires extensive post-inspection processes to validate the safety of parts. Although AM holds enormous promises, no aerospace company currently uses it for high-safety-critical parts, called Class A. This is poised to change within the next five years, as several companies plan to submit Class A AM parts to the FAA for approval. Given the fast-approaching timeline, there's increasing pressure to overcome the hurdles with quality and safety assurance in AM.
If current practices remain unchanged, every AM part intended for high-safety-critical applications will need to undergo expensive and time-consuming CT scanning to ensure its reliability. This will hinder development and opportunities for complex and large AM parts. However, there is a promising alternative – in-situ inspection.
The Role of In-Situ Inspection
During the workshop, Working Group 3: Machine Monitoring –Developing a Five-Year Plan to Allow EASA/FAA Acceptance, highlighted that in-situ inspection can be a reliable method to validate part safety. This solution aligns closely with our work at Phase3D, where we have focused on integrating in-situ inspection technology into AM processes, specifically laser powder bed fusion (PBF), binder jetting (BJT), and cold spray.
In-situ inspection offers a more efficient and scalable method for ensuring the quality of AM parts during production, reducing the need for post-build inspections like CT scanning. However, this technology is still in its developmental phase, and validating its use for FAA and EASA certification will be no small feat. The conversations at the workshop mirrored much of what we discuss internally at Phase3D, underscoring the growing momentum toward in-situ solutions across the industry with the need for true inspection methods that are unit based, repeatable, and reliable.
Phase3D's Approach to In-Situ Validation
At Phase3D, we’ve developed a repeatable and calibratable process that validates every build’s quality by measuring uniform powder distribution and powder deposition across the entire build area. These metrics are just a small portion of the data we collect throughout the AM process. By working closely with our customers, we’re defining process bounds that can be used to determine if a build is “in-control” or not. This data-driven approach is crucial as we move closer to FAA approval for AM parts using in-situ inspection technologies for serial production.
The benefits of in-situ inspection extend beyond just eliminating the need for CT scans. By integrating real-time monitoring into the AM process, manufacturers can gain deeper insight into their builds, allowing them to spot potential issues as they arise rather than during post-inspection. This proactive approach not only saves time but also enhances the reliability and safety of AM parts, bringing the technology one step closer to being approved for high-safety-critical aerospace applications.
The Future of In-situ Inspection
As the push for FAA and EASA approval continues, in-situ inspection stands out as a key enabler for the future of AM in aviation. The next five years will be critical for the development and adoption of this technology. At Phase3D, we're excited to be at the forefront of this movement, contributing to the realization of an aviation future where AM parts are trusted. Through continued collaboration with industry stakeholders, we are confident that in-situ inspection will play a pivotal role in unlocking the full potential of AM for aviation.
To learn more about Phase3D, contact us at sales@phase-3d.com or follow up on LinkedIn.
