Using a Hybrid Approach to Additive Manufacturing Metrology – CT – CMM

Modern Additive Manufacturing (AM) methods often employ subtractive machining to achieve precise dimensional and surface finish characteristics.  This is due to current AM limitations in build precision and surface quality.  These hybrid AM / subtractive components also demand a hybrid approach to measurement.  Internal features on AM parts are difficult or impossible to non-destructively measure using solely traditional metrology methods and so industrial computed tomography (CT) must also be employed.  CT scanning not only allows for precise measurements using metrology CT, but allows for detection of internal defects that are not otherwise able to be seen.  However, well machined portions are best served through other measurement methods due to precision requirements and data characteristics. This can necessitate a hybrid measurement approach.  However, traditional CT scanning and service providers are not trained as metrologists and do not follow particular standards related to metrology – especially ISO17025. Also complicating measurement is the design and datum reference frames used for additive parts that typically follow a traditional machined component print layout.  A layout method following best practices from the casting industry is suggested here. This article explores the methods (GD&T), issues, limitations and current solutions associated with good metrology practices for AM and hybrid AM components.

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How to Handle Quality and Inspection Requirements in Uncertain Times

COVID 19 has literally shut down a majority of the world’s production. As we have talked with our customers over this time, we have found that many have reduced their workforce or have implemented rolling furloughs. The problem is that once you let that skilled person go, they may actually find other work before you can hire them back. So, all of the training that was invested in them is gone. This seems especially true of Quality staff. During each normal business cycle and when things get tight, the quality staff is the first to be reduced. A new staff is then later brought on once the cycle has completed with the requisite experience or they are slowly trained up to a proficient level. This is logically the case as production requirements are lower during these cycles and removing production personnel would immediately and directly hamper the ability to generate revenue.

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Ensuring Accuracy of Gages and Fixtures Through Accredited Calibrations

If we lived in a perfect world the parts you manufacture and the gages used to check them would both be exactly to nominal specifications. At that point a gage would be obsolete and so too would be the metrologist, but we all know that this world is far from perfect and that the best we can ever do in the study of measurements is to provide our best estimate of where the actual value lies along with a provision of uncertainty of measurement that can be traced all the way back to the international system of units.

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Utilizing Computed Tomography (CT) for Printed Circuit Board (PCB) Inspections and Reverse Engineering

3D Engineering Solutions has expertise in inspection and reverse engineering for many different applications.  We combine the best available equipment and a well trained staff to deliver correct results in a rapid manner.

For PCB’s, we use the Nikon X-Tek 160kV Industrial CT Scanner which is designed to meet every need related to the inspection of PCB’s.  It provides up to 160kV and 20W power, a 1µm X-ray focal spot size, and a magnification range of 2x-600x. The detector can also tilt to a max angle of 75° which provides extra flexibility in examining multi-layer boards.

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First Article Inspection – A Comprehensive Guide on How to Perform an FAI

First Article Inspections (FAI) are used to ensure that parts off of new or modified tooling or processes conform to the part design requirements.  This even includes changing the location of manufacture! Yes – this can make a difference sometimes (usually due to different equipment, the same equipment setup slightly differently, environmental conditions, different manufacturing standards, etc).  This includes any time the Form, Fit, or Function could be impacted.

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Drawing Layout Tip – Bill of Material (BOM) Use

Fully defining large assemblies can be a daunting task. It is a task that cannot be ignored, as a well-defined assembly drawing is necessary to properly convey critical details. Manually labeling everything in an assembly drawing can take days and it is very easy for not all the detail to be captured. A solution to this is to add a Bill of Materials or BOM to the drawing.  Modern CAD software (Like SolidWorks – shown in the images below) all have automated means to generate BOMs.  This helps automate the process, reduce chances for error and allows for automatic updates as assemblies change.

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CT Scanning Void Detection – What to Ask for and What to Expect

Radiographic testing is a widely accepted method for finding voids and defects in materials. Makers of castings and solder connections on printed circuit boards have used radiographic testing to detect voids in 2D images and Computed Tomography (CT) in 3D images with excellent results that are well documented. As CT scanning continues to evolve and emerge as the inspection method of choice new challenges arise. Many times customers are unaware of the difference and apply old specifications on their drawings that may no longer apply. Or they do not know the full capabilities of the newer technologies or have not yet defined the specifications for their application.

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ISO17025 Inspection Using Metrology CT

Industrial CT scanning has gained prominence in dimensional data collection technologies with the advent and continual development of additive manufacturing. Now, CT scanning processes are being added to ISO17025 scopes of accreditation and the emergence of Metrology based CT is gaining recognition and acceptance across many industries.

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Using Laser or Structured Light Scanning to Preserve Your Tuned Molds and Dies – Just Like Notre Dame

Your Molds and Dies are critical to your business.  They were meticulously created and iteratively tuned until the parts they produce are within specification.  At that point, they were put into production and no documentation of the final tuned geometry was captured.  This is actually the standard operating procedure for most of the world.  The problem occurs when a part gets stuck and the equipment is cycled again and the tool cracks!  Now you are stuck with having to go through the entire tuning process again.  Or are you? With laser scanning and structured light scanning you may be in luck.

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What Data Collection or Scanning Equipment and Technology is Needed for My Project?

Augmenting Structured Light

Many measurement and reverse engineering requirements require more than simple caliper or micrometer measurements.  Whether you are conducting a First Article Inspection (FAI), troubleshooting a manufacturing issue or reverse engineering a legacy part for improvements, one or multiple of the modern data collection methods may work – but what is best and what are you compromising on by using any particular method?  Do you do this work yourself or hire out an experienced service provider?

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