Part and process qualification for serial production

Qualification of parts and processes in Additive Manufacturing (AM) is crucial for serial production. Especially in sectors with high regulatory standards, it is necessary to provide proof of component properties through a quality assured production. Therefore, this chapter outlines a structured approach from Six Sigma methodology to achieve and maintain a manufacturing process, which meets demanded requirements. The DMAIC cycle with the phases define, measure, analyze, improve, and control (DMAIC) is applied to additive manufacturing. For each phase, theoretical fundamentals are presented, and it is demonstrated how the DMAIC cycle can be implemented with regards to the laser powder bed fusion (LPBF) process, utilizing a use case from railway industry. The aim is to improve the process continuously and to build up a comprehensive process understanding for serial production. Following the Six Sigma approach provides insight into the initial situation of the LPBF process. It enables the user to prioritize critical quality characteristics, to identify possible influences and causes of errors, and to derive actions to stabilize the process and increase process capability. With the knowledge gained about influences and causes of errors, measures can be implemented to eliminate errors in production sustainably. Further, methodology like Six Sigma and DMAIC provides qualification routines, which can be required for the certification of AM production sites by third parties such as certifying bodies. The AM production site can prove that it implements the requirements and guidelines of regulations, which ensures high and reproducible quality for AM of components.

Subjects

Additive manufacturing

DMAIC

House of quality

Process capability

Process qualification

Six Sigma

DDC Class

670: Manufacturing

600: Technology

Options

Part and process qualification for serial production