Mapping the path to certification of metal laser powder bed fusion for aerospace applications

Abstract

Purpose The purpose of this paper is to identify and define the certification lifecycle of laser powder bed fusion for aerospace applications from equipment acquisition and installation to production, part acceptance and continuous improvement activities. Design/methodology/approach A top–down systems engineering approach is performed consisting of concept development, requirements engineering and systems architecting. This approach is taken from the perspective of a production organization. Findings A certification roadmap is proposed that references industry requirements at the relevant phases of the roadmap. Each phase of the roadmap acts as a decision gate for progression to the next. Originality/value Qualification and certification of metal laser powder bed fusion is currently a challenge within the aerospace industry. From an aerospace point of view, the qualification and certification of this relatively new manufacturing process should not have to be any different from traditional manufacturing processes, although with extensive quality control and regulatory oversight. This paper proposes a means for fulfilling these requirements chronologically and provides guidance on ensuring such quality control throughout the manufacturing system lifecycle. This roadmap provides insight into the qualification and certification of laser powder bed fusion for aerospace applications and provides value for future industrial feasibility studies.