Aerospace Testing InternationalAerospace Testing International
  • News
    • A-E
      • Acoustic & Vibration
      • Avionics
      • Data Acquisition
      • Defense
      • Drones & Air Taxis
      • Electric & Hybrid
      • EMC
      • Engine Testing
      • Environmental Testing
    • F-L
      • Fatigue Testing
      • Flight Testing
      • Helicopters & Rotorcraft
      • High Speed Imaging
      • Industry News
    • M-S
      • Materials Testing
      • NDT
      • Simulation & Training
      • Software
      • Space
      • Structural Testing
      • Supplier News
    • T-Z
      • Technology
      • Telemetry & Communications
      • Weapons Testing
      • Wind Tunnels
  • Features
  • Magazines
    • March 2025
    • Dec 2024/Jan 2025
    • Showcase 2025
    • September 2024
    • June 2024
    • Archive Issues
    • Subscribe Free!
  • Opinion
  • Webinars
  • Events
    • All Events
    • Aerospace Test & Development Show
  • Podcasts
  • Videos
  • Suppliers
    • Supplier Spotlights
    • Press Releases
    • Technical Papers
  • Jobs
    • Browse Jobs
    • Post a Job – It’s FREE!
    • Manage Jobs (Employers)
LinkedIn YouTube X (Twitter)
LinkedIn YouTube X (Twitter)
Subscribe to magazine Subscribe to email newsletter Media Pack
Aerospace Testing InternationalAerospace Testing International
  • News
      • Acoustic & Vibration
      • Avionics
      • Data Acquisition
      • Defense
      • Drones & Air Taxis
      • Electric & Hybrid
      • EMC
      • Engine Testing
      • Environmental Testing
      • Fatigue Testing
      • Flight Testing
      • Helicopters & Rotorcraft
      • High Speed Imaging
      • Industry News
      • Materials Testing
      • NDT
      • Simulation & Training
      • Software
      • Space
      • Structural Testing
      • Supplier News
      • Technology
      • Telemetry & Communications
      • Weapons Testing
      • Wind Tunnels
  • Features
  • Magazines
    1. March 2025
    2. Dec 2024/Jan 2025
    3. Showcase 2025
    4. September 2024
    5. June 2024
    6. March 2024
    7. Archive Issues
    8. Subscribe Free!
    Featured
    19th March 2025

    In this issue: March 2025

    Online Magazines By Ben Sampson
    Recent

    In this issue: March 2025

    19th March 2025
    contents and front cover of magazine

    In this issue: December / January 2025

    19th December 2024
    Showcase 2025

    In this issue – Showcase 2025

    6th November 2024
  • Opinion
  • Webinars
  • Events
    • All Events
    • Aerospace Test & Development Show
  • Podcasts
  • Videos
  • Suppliers
    • Supplier Spotlights
    • Press Releases
    • Technical Papers
  • Jobs
    • Browse Jobs
    • Post a Job – It’s FREE!
    • Manage Jobs (Employers)
LinkedIn YouTube X (Twitter)
Aerospace Testing InternationalAerospace Testing International
Opinion

Consider inspections from the start when using 3D printing

Opinion WritersBy Opinion Writers2nd September 20153 Mins Read
Share LinkedIn Twitter Facebook Email

With the use of additive manufacturing (AM) on the increase in the aerospace industry, the lack of standards for testing such products is a source of growing concern.

AM offers total freedom in designing components but at the same time, it makes non-destructive testing (NDT) difficult. Firstly, the more complex the component is both internally and externally, the harder it is to inspect. Another issue is that AM creates a surface finish that is typically rougher than conventional manufacturing processes so inspection methods such as ultrasound, which require a finer surface, are less suitable.

Image courtesy of 3T RPD Ltd.

Internationally, a lot of effort is going into creating inspection standards and there is a real sense of urgency, as I am aware from my own work helping to develop best practice guidelines for BSI and ASTM.

X-ray computed tomography is emerging as the most promising inspection technology but it has its limitations and there is room for improvement to adapt it better to AM although research is taking place in this area. While computed/digital radiography is sometimes used, detecting flaws accurately depends on selecting the correct settings, such as enough projections to cover the part thoroughly.

The ideal solution would be to inspect products during the manufacturing process and take a snapshot of every layer. Some machines already have the capability to do this, but the next step would be to develop systems which could spot the defects themselves and raise the alarm.

Another solution might be to inspect after machining. The smoother surface would potentially allow the use of other inspection methods, although this would add further to the manufacturing cost if the part is found to be defective after machining. Another post-process is hot isostatic pressing, which has shown to reduce the size of internal defects in the parts.

For now, companies should use only experienced practitioners, carry out visual inspection as an initial step, and when in doubt use double testing – where the product is inspected twice by different inspectors. Ultimately, manufacturers need to consider how critical the part is in safety terms and the requirements for inspection when making the decision to use additive manufacturing.

Dr Ben Dutton is a senior research engineer in the Metrology and NDT group at the Manufacturing Technology Centre (MTC), Coventry, UK. An instrumentation scientist, he has over 25 years’ experience in both academia and industry and 12 years’ experience in NDT. Dr Dutton will be speaking about inspection of AM components at 4pm on Tuesday 8 September at Materials Testing 2015 at Telford International Centre. For further information see www.materialstesting.org

Share. Twitter LinkedIn Facebook Email
Previous Article418th FLTS does prerequisite testing for KC-46 program
Next Article Orion parachute system withstands failure test
Opinion Writers

Related Posts

Materials Testing

Giving green thrusters a boost

15th April 20256 Mins Read
Gerard Van Es, Principal Advisor of Flight Safety and Operations at NLR
Opinion

Academic Insight: Testing to help stop runway overruns

1st April 20254 Mins Read
NDT

Q&A: Daniel Richard, Solutions Development Expert, Eddyfi Technologies

3rd March 202514 Mins Read
Latest Posts

Industry Adoption of 3D Optical Surface Gauges

21st May 2025

NDT: Robotics and software spur innovation

21st May 2025

Wisk and NASA to partner on US autonomous flight operations and standards

20th May 2025
Supplier Spotlights
Our Social Channels
  • Twitter
  • YouTube
  • LinkedIn
Getting in Touch
  • Subscribe To Magazine
  • Contact Us
  • Meet the Team
  • Media Pack
Related Topics
  • Aircraft Interiors
  • Business Jet Interiors
FREE WEEKLY NEWS EMAIL!

Get the 'best of the week' from this website direct to your inbox every Wednesday

© 2023 Mark Allen Group Ltd | All Rights Reserved
  • Cookie Policy
  • Privacy Policy
  • Terms & Conditions

Type above and press Enter to search. Press Esc to cancel.