Mechanical and Material Verification: In order to insure a high quality component that is devoid of defects that could lead to part failure, a comphrensive test campaign is employed for all parts that are slated to fly. Test coupons are printed simultaneously for every build in and out of plane, and are measured destructively for ultimate strength, yield strength, longation and Young’s modulus. Density cubes are also fabricated from which cross-sections are polished and examined with optical microscopy. Additionally, thin-walled, fully enclosed pyramid structures are fabricated in order to hermetically seal a sample of powder originating from the build process for later examination if required. The printed artifacts are then nondestructively tested by subjecting them to CT scans in order to identify internal voids of flaws, and also to check the dimensionality of the AM- produced component. If required, structural testing of the components is also performed at this stage.
*** If the testing campaign results indicate that the manufactured component is lacking in structural fidelity, the additive manufacturing process step is re-examined,
vvv the process parameters are adjusted, and the artifacts and coupons are manufactured again with the new parameter settings.vvv
The new artifacts and coupons are re-tested as described above. This process continues until it is determined that the parts are of high quality, are structurally sound and suitable for flight.***
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