Accelerating Metal 3D printing Certification:

In highly regulated industries like aerospace, defense, and medical manufacturing, success in additive manufacturing isn't just about producing complex metal parts. The real challenge is proving that every part can be manufactured consistently, predictably, and in compliance with stringent qualification requirements.

That's why process capability has become such a critical factor in additive manufacturing adoption.

A recent Titanium Process Capability study from 3D Systems highlights how Direct Metal Printing (DMP) technology (LPBF) and LaserForm^® Ti Gr23 (A) material can help manufacturers reduce qualification risk and accelerate the certification of critical titanium components.

DMP is 3D Systems’ advanced Laser Powder Bed Fusion (LPBF) metal 3D printing that delivers extremely low oxygen rates for greater reliability and repeatability of metal parts production.

Certification Begins with Process Confidence

When qualifying a new manufacturing process, regulators and quality teams need objective evidence that the process will repeatedly produce parts that meet specification. Consistency, traceability, and repeatability are just as important as part performance.

3D Systems developed its titanium DMP process with these requirements at the forefront. Through extensive process characterization, equipment validation, material control, and statistical analysis, the study demonstrates a manufacturing process designed to support demanding qualification programs.

Built for Repeatable Results

One of the biggest contributors to process stability is environmental control during production.

3D Systems' DMP platforms utilize a unique vacuum-based chamber architecture combined with exceptional inert atmosphere control. By minimizing exposure to oxygen and moisture, manufacturers can maintain tighter control of powder chemistry and produce highly consistent mechanical properties across builds.

For organizations pursuing certification, that level of control translates into greater confidence that production parts will continue to meet requirements over time.

A Robust Process Window

A key element of the study was a comprehensive Design of Experiments (DoE) investigation examining variables such as laser power, feed rate, argon flow, and build size.

The results were encouraging: variations within the validated operating window showed no practical significant impact on critical quality attributes. In other words, the process demonstrated strong robustness, helping manufacturers reduce the risk of unexpected variability during qualification and production.

Supporting ASTM-Aligned Qualification Strategies

Rather than starting from scratch, manufacturers can leverage an approach that aligns with the risk-based qualification framework outlined in ASTM F3434.

The methodology incorporates equipment validation, process validation, and product validation, while also allowing organizations to utilize existing material databases and machine capability studies. This can significantly reduce redundant testing efforts and streamline the path toward certification.

Six-Sigma Mechanical Performance

Perhaps most impressive are the mechanical property results.

Testing of Ti6Al4V Grade 23 components demonstrated process capability exceeding six-sigma performance across critical mechanical properties, including:

• Yield strength
• Ultimate tensile strength
• Elongation
• Reduction of area

The study reported zero out-of-specification mechanical test results, providing strong evidence that the process is capable of delivering the consistency required for critical applications.

Extending Powder Life Without Sacrificing Traceability

Powder management is another important consideration for regulated production environments.

3D Systems' continuous powder management strategy maintains strict control over powder chemistry while preserving full lot traceability. The study found that oxygen levels remained within specification throughout powder reuse cycles, helping manufacturers improve production efficiency without compromising compliance or quality requirements.

Moving from Qualification to Production Faster

Ultimately, manufacturers are looking for ways to reduce certification timelines and bring products to market more quickly.

The combination of proven process capability, controlled powder management, validated equipment performance, and more than a decade of experience producing critical applications gives organizations a stronger foundation for qualification and certification activities. The result is reduced risk, greater confidence in part approval, and a faster path from design to production.

Ready to Learn More?

If you're working to qualify titanium additive manufacturing for aerospace, defense, medical, or other mission-critical applications, the Titanium Process Capability White Paper provides valuable insight into the data, methodologies, and process controls behind 3D Systems' DMP technology and LaserForm^® Ti Gr23 (A) material.

Download the Titanium Process Capability White Paper to learn how a validated, statistically proven AM process can help accelerate certification and simplify qualification.

Or speak with a 3D Systems expert to discuss your certification and validation requirements.