Fraunhofer IPA and Imprintec develop robot-assisted inline quality assurance for 3D-printed components.

In June 2024, Fraunhofer IPA and Imprintec GmbH achieved a major milestone in the automated quality assurance of 3D-printed components.

Within the framework of the research project »Efficient quality assurance method for bionically optimized and resource-saving 3D-printed components« (Enabl3D), funded by the Federal Ministry for Economic Affairs and Climate Action, Imprintec, together with VisiConsult – X-ray Systems & Solutions GmbH and Fraunhofer IAPT, developed and successfully tested a corresponding testing procedure.

In the sub-project »Robot-assisted Inline Quality Assurance«, Fraunhofer IPA and Imprintec collaborated closely to connect the innovative testing module to a flexible six-axis industrial robot, thus enabling the automated inspection of components directly in the production line.

Initial successful tests have already been carried out on various components, including series production parts.

In Detail

Additive manufacturing or 3D printing can significantly reduce CO2 emissions, particularly in the aviation industry. Here, bionic metal 3D-printed lightweight components can reduce fuel consumption and minimize material requirements such as waste. However, large-scale use requires high economic efficiency and reliable quality. This is where the Enabl3D project comes in.

To develop efficient quality assurance, the project partners Fraunhofer IAPT, VisiConsult GmbH, and Imprintec GmbH have combined three testing methods:

• Indentation Testing: Measuring material properties directly on the component (tensile strength, yield strength, ductility, anisotropy).
• High-Resolution Process Monitoring: Verifying process stability to identify critical areas and transfer locally measured properties to the overall component.
• µCT Examinations: Non-destructive testing of areas already identified as critical during the printing process.

The project succeeded in developing a procedure for quality assessment of additively manufactured components: The in-situ monitoring of Fraunhofer IAPT identifies areas that need to be examined with CT scans. The CT scans are carried out robot-assisted and enable the extraction of critical component defects. Indentation testing locally determines the mechanical component properties. Complemented by simulations, the combination of the three testing methods allows conclusions to be drawn about the individual component properties.

In the sub-project on the »Integration of Hardness Testing Technology«, Fraunhofer IPA and Imprintec GmbH connected 6-axis industrial robots. Initial successful tests were carried out on components, including those from series production. The partners were able to effectively contribute their expertise in the fields of manufacturing technology, measurement technology, and the integration of new robot-guided tools and measurement technology.

The results pave the way for Additive Manufacturing in new application areas in the field of series or individual part production in aerospace, automotive, and medical technology.

The testing process and the initial results can be seen in the video.

Insights into the Project