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CASE STUDIES

DARPA Study Validates PrintRite3D® Quality Control Process for Certification of Metal Parts

A six-year project with DARPA that relied on Sigma’s PrintRite3D® technology has drawn three key conclusions. First, PrintRite3D® demonstrates and ensures process consistency and product quality in metal additive manufacturing. Second, this technology can also monitor additive manufacturing equipment health. Finally, PrintRite3D® can be used to certify quality and certify components without destructive testing or CT scanning – saving time, money and materials.

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The relationship between In-Process Quality Metrics & Computational Tomography (CT) in Additive Manufacturing of Metal Parts

What if you could see and analyze the structure of a 3D-printed part while it was being made? You could then have high confidence in the manufacturing process. You’d also be able to adjust the process in real time to further assures quality. Sigma Labs has developed a method to do just that, with results comparable and complementary to CT testing, as this case study demonstrates.

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In-situ Melt Pool "Thermal Signature" Defect Detection of Recoater Failure Using Co-Axial Planck Thermometry

Sigma Labs’ proprietary Thermal Energy Planck (TEP™) metric identifies variances in the production of 3D metal parts in real time. Thus, using TEP™ allows for intervention and adjustment of the manufacturing process in real time, making the process more efficient and less costly. This in turn saves time, money and can ensure product quality in metal additive manufacturing.

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Evaluation of Quality Signatures™ using In-Situ Process Control during Additive Manufacturing with Aluminum Alloy AlSi10Mg Part 2

This document reports on the second in a series of experiments to demonstrate the capabilities of Sigma Labs, Inc. (Sigma) PrintRite3D INSPECT® software to determine the effect of intentional changes in an independent process input variable (laser power) on dependent or response data mined in-situ on a layer to layer and part to part basis.

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The Relationship Between Melt Pool Monitoring Metrics and Archimedes Density

Metal additive manufacturing today leaves skilled practitioners with little to no insight into the process. Nor does it provide in-process feedback about part quality. Until now. Sigma has demonstrated that its quality metric TED™ exhibits a strong correlation to both global energy density and Archimedes’ density, both established and trusted measures of part quality in the metal additive manufacturing industry.

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In-Situ Process Mapping using Thermal Quality Signatures™ during Additive Manufacturing with Titanium Alloy Ti-6Al-4V

The current study was designed with three experimental purposes in mind: 1) establish a material specific process map using in-situ Thermal Quality Signatures™ and ex-situ physical property data; 2) draw a one-to-one correlation between in-situ dependent data quality metrics and ex-situ dependent data property metrics; and 3) set the stage for closing the loop by affording the opportunity to self-correct the process in real time.

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Evaluation of Quality Signatures™ using In-Situ Process Control during Additive Manufacturing with Aluminum Alloy AlSi10Mg - Part 1

This build was designed to establish a correlation between in-process dependent data mined from in-situ sensor raw traces signals, independent process input variables for example laser power, and post-process dependent data measured during destructive metallographic testing for porosity of as-built specimens.

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Sigma Labs welcomes your questions as well as opportunities for demonstration and collaboration. Please contact our technical team for more information.

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