North Carolina State University discovers a new method to achieve automated quality control of 3D printed parts
Researchers from North Carolina State University have established a new technique for manufacturers to achieve automated quality control of metal machine 3D printed parts, specifically in the finishing process. By utilising this new technique users will be able to discover potential defects without removing parts from the manufacturing equipment, speeding up production time and making it more efficient.
“One of the reasons people are attracted to 3D printing and other additive manufacturing technologies is that these technologies allow users to quickly replace critical machine components that are otherwise difficult to make outside of a factory,” said Brandon McConnell, co-corresponding author of a paper on the work and assistant research professor in NC State’s Edward P. Fitts Department of Industrial and Systems Engineering.
“And additive manufacturing tools can do this as needed, rather than dealing with supply chains that can have long wait times. That usually means using 3D printing to create small batches of machine parts on demand.”
Once a metal machine part is printed, said part needs to complete additional finishing processes and be measured to ensure that the part meets critical tolerances. Traditional methods see a part being taken out of the required manufacturing equipment, measuring it, and then placed back for adjustments to be made.
“This may need to be done repeatedly, and can take a significant amount of time,” continued McConnell. “Our work here expedites that process.”
This new technique integrates 3D printing, automated machining, laser scanning, and touch-sensitive measurement technologies with relevant software to create a larger automated system.
How does this new technique work?
- The user loads the software file which includes the measurements of the desired part.
- Said part is 3D printed with metal support structures.
- The printed piece is then mounted in a finishing device so that lasers can scan the part to provide dimensional measurements.
- These measurements are then put into a software program which can provide the critical tolerances, with any irregularities eliminated.
- Finally, the finishing device can manipulate the orientation of the part, allowing it to be measured by a touch-sensitive robotic probe to ensure the part’s dimensions.
“We were able to finish the part in 200 minutes using conventional techniques; we were able to finish the same part in 133 minutes using our new technique,” said McConnell. “Depending on the situation, saving 67 minutes could be incredibly important. Time is money in most professional settings. And in emergency response contexts, for example, it could be the difference between life and death.”
This work focuses on printing and finishing machine parts that include circles or cylinders, like pistons. However, the method has the potential to be adapted for machine parts with other features.
“All of the hardware we used in this technique is commercially available, and we outline the necessary software clearly in the paper – so we feel that this new approach could be adopted and put into use almost immediately,” concludes McConnell. “And we are certainly open to working with partners who are interested in making use of this technique in their operations.”