Additive Manufacturing – Standards.
Alex Price, Lead Programme Manager.
Copyright © 2013 BSI. All rights reserved.
So how many standards are there?
BS 8445:2012 - Bath and shower mats. Testing.
PAS 181:2014 - Smart city Framework. Guide to
Assessment of slip resistance properties safety
establishing strategies for smart cities and
signs
communities
BS 185-6:1970 - Glossary of aeronautical
and astronautical terms. Ballistic and BS 8888:2011 - Technical product documentation
guided missiles and specification
Copyright © 2013 BSI. All rights reserved. 03/02/2017
2 2
Who sets all these standards?
• Someone has an idea?
National Standards Body
Copyright © 2013 BSI. All rights reserved. 03/02/2017
3 3
Why adopt a standard/s:
• Required: • Recommended: • Information:
• The standard may form part of a • A good rationale would be • Elements from a standard could be
contract, presented, adoption of the standard taken into company best practise
• The Standard may be part of may improve business performance, without full adoption,
obligation to CE or some other • May improve business practice, • May form part training potentially
quality mark, • A very large percentage of export is for employees,
• The Standard may be referred to in influenced by the European and • Could form guidance to day to day
legislation, international standards business, business.
• The Standard may be required • May form part training potentially for
within the supply chain. employees,
• Interoperability with other
standardised products or
components.
Copyright © 2013 BSI. All rights reserved. 03/02/2017 4
Additive Manufacturing – where’s the hype
Image courtesy of NIST Economist February 2011.
Image new scientist July 2012.
Copyright © 2013 BSI. All rights reserved. 03/02/2017 5
Why Standardisation?
• Any number of reports have highlighted the need.
• Industry request.
• Key Challenged hindering advancement of AM over the next ten years.
• Report by the IQPC
• 76% of respondents highlighted certification of finished parts and products.
• 48% Quality & standardisation of material inputs
• 36% Questionable quality of finished parts
Copyright © 2013 BSI. All rights reserved. 03/02/2017 6
So many processes, materials and outputs under the additive manufacturing
banner.
• There are a number of processes which fall under the Additive Manufacturing label. Which vary in
material, process, final shape, surface finish, geometrical shape required. The American Society for
Testing and Materials (ASTM) group “ASTM F42 – Additive Manufacturing”, formulated terminology
defining range of Additive Manufacturing processes into 7 categories ISO/ASTM52900-15 Standard
Terminology for Additive Manufacturing – General Principles – Terminology:
• VAT Photopolymerisation
• Binder Jetting
• Material Jetting
• Material Extrusion
• Powder Bed Fusion
• Sheet Lamination
• Directed Energy Deposition
Copyright © 2013 BSI. All rights reserved. 03/02/2017 7
Top level overview of the development of standards.
NIST publication on AM.
Copyright © 2013 BSI. All rights reserved. 03/02/2017 8
What new areas is Additive manufacturing linked to?
• Machine Safety
• Laser safety
• Contained atmospheres
• Metrology:
• Both established mechanical properties
• state of the art ultra-high accuracy
• multi-sensory coordinate measurement machines.
• Non Destructive Evaluation in-process and post process:
• For post build inspection for both surface and sub-surface monitoring, digital x-ray, X-ray CT
ultrasound. Eddy current may be used for surface and close to surface monitoring.
• For in-process sensors, thermal and optical imaging.
• Intelligent automation:
• Complex automation
• Robotics
• Sensor technology, embedded.
Copyright © 2013 BSI. All rights reserved. 03/02/2017 9
What is Quality management for AM?
• System:
• Level of assurance of part.
• Aerospace
System: Some possible
• Robust systems of traceability. certification type
• Standards standard. Possibly ISO
• Training and 9001 or equivalent
• New technology requires it industrial sector such as
aerospace (AS 9120) or
• Process: medical (ISO 13485) for
• What AM process is the most appropriate for your task. example.
• Choice of materials.
• Knowing your key parameters.
Material: Consistent and Process: With currently
• In process monitoring.
reliable feedstock seven different
• Post processing. material. Key processes, and
• What needs to be done to get the part up to required levels. characteristics reported variations of different
• Next process consideration. such as; chemical materials and grades of
composition and size. in the use.
• Materials:
• What AM material can be used.
• Is it the most appropriate for your task.
• Choice of materials.
Copyright © 2013 BSI. All rights reserved. 03/02/2017 10
So what are the standards program currently?
• ISO 17296-2:2015 Additive manufacturing -- General principles -- Part 2: Overview of process categories and feedstock
• ISO 17296-3:2014 Additive manufacturing -- General principles -- Part 3: Main characteristics and corresponding test methods
• ISO 17296-4:2014 Additive manufacturing -- General principles -- Part 4: Overview of data processing
• ISO/ASTM 52900:2015 Additive manufacturing -- General principles -- Terminology 60.60
• ISO/ASTM DIS 52901.2 Additive manufacturing -- General principles -- Requirements for purchased AM parts
• ISO/ASTM NP 52902
• Additive manufacturing -- General principles -- Standard test artifacts
• ISO/ASTM DIS 52903-1 Additive manufacturing -- Standard specification for material extrusion based additive manufacturing of plastic
materials -- Part 1: Feedstock materials
• ISO/ASTM CD 52903-2 Additive manufacturing -- Standard specification for material extrusion based additive manufacturing of plastic materials
-- Part 2: Process -- Equipment
• ISO/ASTM NP 52905 Additive manufacturing -- General principles -- Non-destructive testing of additive manufactured products
• ISO/ASTM DIS 52910.2 Guidelines for additive manufacturing design
• ISO/NP TR 52912 Design of functionally graded additive manufactured parts
• ISO/ASTM 52915:2016 Specification for additive manufacturing file format (AMF) Version
• ISO/ASTM 52921:2013 Standard terminology for additive manufacturing -- Coordinate systems and test methodologies
Copyright © 2013 BSI. All rights reserved. 03/02/2017 11
How can standards support the development? Machinery
Safety
Post-
In process process
monitoring monitoring
Types of AM
processes
Mechanical,
and
thermal, etc
calibration
Testing
Consistent
Dimensional raw
metrology Guidance Data materials
and best formats and
practise retention
Copyright © 2013 BSI. All rights reserved. 03/02/2017 12
Types of AM process
• Material extrusion
• ISO/ASTM CD 52903-2Additive manufacturing -- Standard specification for material extrusion based additive
manufacturing of plastic materials -- Part 2: Process -- Equipment
• Powder bed fusion
• Draft DIN 35224: Welding for aerospace applications – Acceptance inspection of powder bed based laser beam
welding machines for additive manufacturing”
• Draft DIN TBD: Aerospace — Powder for additive manufacturing with powder bed process – Technical
specification
• Material jetting
• Binder jetting
• Directed Energy deposition
• Sheet lamination
• Vat polymerisation
• Draft DIN TBD: “Welding for aerospace applications – Qualification of operators for additive manufacturing
equipment”
• Draft DIN TBD: “Testing and Inspection of additively manufactured products”
• ISO 17296-2:2015 Additive manufacturing -- General principles -- Part 2: Overview of process categories and
feedstock Copyright © 2013 BSI. All rights reserved. 03/02/2017 13
In process monitoring
• AM NDT standards will require consideration of particular number of defects and assessment of the
surface monitoring during the build, where thermal monitoring, optical imaging and geometrical
monitoring would be useful. For in-process sensors to provide non-destructive evaluation and allow
for early detection of flaws/defects, also modelling on residual stresses based on work at the STFC,
neutron source.
• Thermography:
• BS ISO 18434-1:2008 Condition monitoring and diagnostics of machines. Thermography. General procedures
• ASTM E1311-14 Standard Practice for Minimum Detectable Temperature Difference for Thermal Imaging Systems
• Visual inspection:
• Very much an objective method based human experience and hence virtually impossible to standardise.
• Ultrasonic:
• BS EN 583-1:1999 Non-destructive testing. Ultrasonic examination. General principles
• Computer tomography (CT):
• BS EN 16016-3:2011 Non destructive testing. Radiation methods. Computed Tomography. Operation and
interpretation
Copyright © 2013 BSI. All rights reserved. 03/02/2017 14
Post processing monitoring
• AM NDT standards will require consideration of particular number of defects and assessment of the
surface monitoring during the build, where thermal monitoring, optical imaging and geometrical
monitoring would be useful. For post build inspection the following techniques may be used for both
surface and sub-surface monitoring, digital x-ray, X-ray CT ultrasound. Eddy current may be used for
surface and close to surface monitoring.
• Generate best practice guide showing NDT methods potential to inspect AM defects not covered by
current standards.
• Current Work Item: WK49798 – Standard Guide for Intentionally Seeding Flaws in AM Parts
• WK47031 – Standard Guide for Nondestructive Testing of AM Metal Parts Used in Aerospace
Applications
Copyright © 2013 BSI. All rights reserved. 03/02/2017 15
Machine Safety
• Many of the Additive machines are on the market, so obviously comply with the machinery directive
2006/42/EC, making use of the standards below:
• Some considerations on machinery safety:
• Laser
• Explosive atmospheres
• Hot melt flow of materials
• Residual powders
• EC Directive 2006/42/EC standards dealing with the essential requirements.
• BS EN ISO 12100:2010 Safety of machinery. General principles for design. Risk assessment and risk reduction
• BS EN ISO 13849-1:2015 Safety of machinery. Safety-related parts of control systems. General principles for
design
Copyright © 2013 BSI. All rights reserved. 03/02/2017 16
Consistent raw materials
• The raw materials are often in the form of powders or wires that can be melted and shaped by a laser.
• Consistent raw materials.
• Goes someway to consistent outputs.
• Guarantees process consistency.
• Characterization of Additive Manufacturing Materials involves developing measurements and standards
for characterizing powdered metals—raw materials for additive manufacturing—in terms of particle
size and shape, chemical consistency and size consistency.
• Work undertaken by NIST.
• ISO 17296-2:2015 Additive manufacturing -- General principles -- Part 2: Overview of process categories and
feedstock
• ISO/ASTM DIS 52903-1 Additive Manufacturing -- Standard Specification for Material Extrusion Based Additive
Manufacturing of Plastic Materials -- Part 1: Feedstock materials
Copyright © 2013 BSI. All rights reserved. 03/02/2017 17
Data formats and retention
• 3D printing uses digital chain of information
• Many CAD formats extant, only some used for data transfer.
• Information
• Process
• Geometry
• Additive manufacturing file formats:
• STL: proprietary, but de-facto standard through frequent adoption by CAD software providers
• STEP: ISO 10303-242:2014 Industrial automation systems and integration -- Product data representation and
exchange -- Part 242: Application protocol: Managed model-based 3D engineering
• STEP-NC: ISO 14649-1:2003 Industrial automation systems and integration -- Physical device control -- Data
model for computerized numerical controllers -- Part 1: Overview and fundamental principles
• AMF: BS ISO/ASTM 52915:2016 Specification for Additive Manufacturing File Format (AMF) Version 1.2
• 3MF:industry consortium including Microsoft, HP, Fit, formLabs, etc.
Copyright © 2013 BSI. All rights reserved. 03/02/2017 18
Guidance and best practise
• With the number of processes out there to choose from which one is the best?
• Considerations (Design for manufacturer/Design for testing):
• Distinguishing Intermittent Stages of AM
• Processing
• Geometry Characteristics Specific to Additive
• Material Definition
• Datum/s
• Functional Requirements
• Post and pre Inspection
Copyright © 2013 BSI. All rights reserved. 03/02/2017 19
Why a standards is needed.
Technical Report for the Design of Functionally Graded Additive
Manufactured Parts:
• Ensuring interoperability
• The report will review of current capabilities and limitations of existing CAD and Finite Element Method (FEM) software
that can support the production of Functionally Graded Additive Manufactured parts and existing software has been
used to simulate FG materials that have variation of mechanical properties such as varying elastic modulus of the FGM
piece.
• Creating market access
• It will be relevant for those directly involved in the process of product design development and for those responsible for
the material formulation and engineering.
• Provide source of knowledge
• The report is aimed at all those involved in Additive Manufacturing industry to describe the concept of functionally
Graded Additive Manufacturing.
• Creating market acceptance
• The report will discuss existing gaps in knowledge, the current limitations and suggesting areas for future work. In
particular, the report will recommend how future guidelines or standards could be developed from this study.
Copyright © 2013 BSI. All rights reserved. 03/02/2017
20 20
Dimensional metrology
• The principal check in manufacturing.
• Dimensional metrology instrumentation and post-measurement analysis techniques that will allow
them to keep processes under tight control.
• Why are checking?
• Reducing scrap rate and therefore enhancing environmental sustainability.
• What are checking for?
• Quality.
• 378 published standards:
• BS 8888 Technical product documentation and specification
• BS 8887-1:2006 Design for manufacture, assembly, disassembly and end-of-life processing (MADE) - General
concepts, process and requirements
• BS 6808-3:1989 Coordinate measuring machines - Code of practice
Copyright © 2013 BSI. All rights reserved. 03/02/2017 21
Mechanical, thermal, chemical Testing-AM matrix.
• List of materials properties:
• Anelasticity
• Ductility
• Elastic deformation
• Elastic recovery
• Strain
• Stress
• Hardness
• Modulus of elasticity
• Plastic deformation
• Poisson’s ratio
• Proportional limit
• ShearTensile s
• trengthToughness
• YieldingYield strength
Copyright © 2013 BSI. All rights reserved. 03/02/2017 22
Standards in systems
• The final guidance also includes recommendations for standards in
systems.
• Connector materials
• BS EN 13544-2:2002+A1:2009 Respiratory therapy equipment. Tubing and
connectors
• BS ISO 17256. Anaesthetic and respiratory equipment. Respiratory therapy
tubing and connectors
• ISO 80369-2:2012, Small-bore connectors for liquids and gases in healthcare
applications — Part 2: 62 Respiratory small-bore connectors
• Flow
• BS EN ISO 15002:2008 Flow-metering devices for connection to terminal units of
medical gas pipeline systems
• Inadequacy of color-coded and labelled connectors
• ISO 7000:2004, Graphical symbols for use on equipment – index and synopsis.
• Labelling
• EN 980, Symbols for use in the labelling of medical devices
• Usability and human factors testing
• BS EN 1041 Information supplied by the manufacturer of medical devices
Copyright © 2013 BSI. All rights reserved. 03/02/2017 23
Additive manufacturing Standard systems
Copyright © 2013 BSI. All rights reserved. 03/02/2017 24
So where else are AM/3DP standards heading
• Legacy parts
• Reverse engineering
• Documents retention
• Comparison testing
• 3D Hubs
• 27 813 printers on the network
• 90% are not fully utilized
• At least of one of these printers chocolate
• Printing at scale
• Nano scale printing
• Functional materials printing
• Embedded electronics
• Printed electronics
Copyright © 2013 BSI. All rights reserved. 03/02/2017 25
Definition of Digital Manufacturing: e-Enablement of value chain
optimisation
• Digital manufacturing is the collaborative transformation of manufacturing through
the exploitation of advances in ICT
• Digital manufacturing transformation enables new supply chain and operations
capabilities (scenarios) to emerge that exploit advances in digital technologies, devices,
data analytics, data integration and management across the value chain in many
sectors
• Digital manufacturing requires the development of new systems engineering
competencies (systems modeling, simulation and interface design) and skills (attitudes)
across the manufacturing value chain (R&D, design, supply, production, distribution, in
service, disposal
• Digital manufacturing offers significant national and corporate competitive advantage
through affordable flexibility, personalisation and product/service tailoring
Copyright © 2013 BSI. All rights reserved. 26
10 scenarios for digital adoption by manufacturing supply chains
1. Automated 2. Digital 3. Real-time Factory 4. Flexible Factory 5. Digital Production
e-Sourcing Factory Design Scheduling Automation Processes
… … … … … …
6. e-Commerce 7. Extended Supply 8. Digital 9. Digital Supply 10. Product Lifecycle
Fulfilment Chain (near) Product Quality Network Design Management
real-time Monitoring
… … … … … …
© Centre for International Manufacturing, IfM 2016
Copyright © 2013 BSI. All rights reserved. 27
Copyright © 2013 BSI. All rights reserved. 03/02/2017
28 28
