A case study for qualification of a structural additively manufactured one-off component

Additive manufacturing is well suited for producing one-off components, but has inherit risks such as limited control and insight into the manufacturing process and part-specific anomalies that can arise. This study demonstrates the qualification framework for a one-off structural additive part—a force transducer for NASA’s wind tunnels. The framework leverages a publicly available additive specification and combines it with build specific characterization. Recommendations for satisfying specification requirements, such as powder chemistry requirements, are discussed within the context of a single build. Also, future opportunities to more fully leverage existing specifications are covered. Coupon testing validated that minimum established tensile properties were achieved, and a production article evaluation investigated the effect of geometry on the microstructure. Parts were screened using non-destructive evaluation techniques, which identified a critical defect in two of the four printed parts. Following screening, one of the four parts was finish machined, and it was instrumented to make a force transducer. Calibration and a series of proof loadings were carried out that validated the structural integrity and instrument performance. The transducer is planned to be used in an upcoming wind tunnel test.