Proven NDT Methods Adapted to Additive Manufacturing

The Challenge

Additive manufacturing requires quality control methods that can detect internal defects and verify material properties without destroying valuable parts. While various NDT approaches exist, many are complex, expensive, or unproven for AM-specific defect types. Meanwhile, the impulse excitation technique has been successfully used for decades in traditional manufacturing sectors—refractories, cement, friction materials—where similar quality verification needs exist.

The Solution

This research demonstrates how IET methodology from established industries can be directly adapted for additive manufacturing inspection. The technique’s fundamental physics remain the same: resonant frequency and damping measurements reveal internal structure, density, and defects regardless of whether the part was cast, sintered, or 3D printed.

The approach enables rapid screening of AM parts for internal defects by comparing measured frequencies against known-good reference samples. Material property verification occurs non-destructively, allowing 100% inspection of production parts rather than destructive sampling that wastes expensive AM components.

Results

The paper validates that IET principles proven over decades in traditional industries transfer effectively to additive manufacturing quality control. AM users gain access to a mature, reliable inspection methodology with established industrial track record, rather than developing new approaches from scratch. This accelerates AM adoption by providing confidence in part quality without requiring novel or expensive inspection equipment.