Germany-based innovative solutions provider Dimensionics Density which automates technology like 3D printing to enhance quality and production, has elaborated how density determination is important in Additive Manufacturing in its recent press release.
By Density determination, the AM industry can measure and assess the material density of 3D printed parts, making them achieve the desired specifications and standards. It analyses how closely the actual material density of the 3D printed parts matches the desired or intended density of the object.
Unlike the traditional manufacturing process, where materials are moulded or cast as a whole, in additive manufacturing, the makers use 3D printing techniques to create hard-to-access internal structures of 3D-printed parts. The process involves depositing several thin layers of materials which results in voids, defects and inconsistencies in the 3D printed part.
Additionally, the scattering of powder particles across the bed in 3D printing processes like Metal Binder Jetting can lead to overheating of the alloys and introduce gas pores into the 3D printed structure.
These bottlenecks in AM can be addressed through density determination that ensures each layer is fused correctly with no contamination or gas pores, thus achieving the desired material properties, structural integrity, and performance.
Helping achieve the desired material properties
Material properties of 3D printed parts is closely linked to density determination. The density of the AM parts influences the mechanical strength, thermal conductivity, electrical conductivity and other such material properties.
High-density 3D printed parts used in aerospace, Automotive and construction industries have high mechanical strength as density is directly proportional to it. This provides the necessary structural integrity required in such high-stress and load-bearing industries.
3D-printed parts with optimized thermal conductivity are ideal for heat-sensitive applications like electronic devices and heat exchangers. Here too, accurate density determination results in superior thermal performance in the AM parts.
For the telecommunications and electronics industry, the electrical conductivity of 3D printed parts is important and density determination ensures that metal 3D printed parts meet precise electrical conductivity requirements.
Ensuring the structural integrity of the 3D-printed parts
The structural integrity of metal 3D printed parts depends on the density determination as it determines the degree of material consolidation and fusion achieved during the 3D printing process. High-density AM parts are more resistant to cracks as it signifies that the metal particles or layers have effectively bonded together. Whereas a low-density metal AM part means incomplete fusion as seen by defects like voids and pores. This reduces the structural integrity of the 3D printed parts making it difficult to use in industries like healthcare, aerospace and automotive.
High-density metal AM parts are more likely to meet quality and safety standards set by the industries while low-density parts will have unpredictable failure modes and diminished load-bearing capacity. Hence, density determination is critical in ensuring the strength and reliability of AM parts so that they can be used in real-world applications.
Also, the consistency of high-density AM parts has a greater lifespan and meets design specifications more precisely.
New automated density determination methods
Cutting-edge density determination techniques like those offered by Dimensionics Density help manufacturers achieve optimal part quality and performance. The company combined the manual Archimedes density determination method with modern automation technology.
Earlier the AM industry used micrographs, computed tomography (CT), or the manual Archimedes method which resulted in variations in the accuracy and resolution of the density determination process. Most of these technologies have drawbacks in repeatability and successful defect detection.
While Micrographs helped in gaining insight into AM parts porosity it required significant time, cost and manual labor to do it. Also, it often led to the destruction of the part. CT, on the other hand, couldn’t detect small pores and required the use of expensive instruments. Manual Archimedes were susceptible to environmental changes and human handling, making it difficult to repeat the process.
In Dimensionics Density’s density determination solution, 3D printed parts are placed identically onto scales designed to insulate from vibrations. The climate sensors in the system also record environmental conditions like temperature, air pressure, and water temperature, resulting in automated and accurate density measurements of the AM parts.
In additive manufacturing, the role of density determination can’t be undermined and Dimensionics seeks to help AM companies with that.
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