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Copyright © 2015, Sigma Labs, Inc. 1

Additive World Conference Industrial 3D Printing Conference Eindhoven, The Netherlands March 4-5, 2015

Mark Cola President and CEO Sigma Labs, Inc., 3900 Paseo del Sol, Santa Fe NM 87507

“If you want to teach people a new way of thinking, don’t bother trying to

teach them. Instead, give them a tool, the use of which will lead to new ways

of thinking.”

Buckminster Fuller

20th century inventor and visionary


Sigma Labs Overview Challenges for Metal AM Definitions

Design Intent

IPQA® vs. PPQA

Rapid Qualification

Required Solutions IPQA® Tools – PrintRite3D® Products Bridging the gap – Prototype to Production Applications of IPQA® to AM Government Programs Contract AM Services with IPQA® Summary


Mission Sigma Labs delivers intrinsically superior AM parts through use of its 3rd party, platform

independent In-Process Quality Assurance™ systems for additive manufacturing clients seeking rapid qualification solutions

Corporate Office Santa Fe, NM dba,B6 Sigma, Inc.

Products PrintRite3D® quality assurance suite of software for additive manufacturing

Services Consulting Engineering – design and metallurgy for AM

AM parts making – EOS M290 system

4 Copyright © 2015, Sigma Labs, Inc.


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System Installations


Santa Fe, NM

1. Getting the Right Quality

For the most critical applications like aerospace and defense, there is still a lot of variation part-to-part, run-to-run, and machine-to-machine. This requires extensive post-process inspection.

2. Getting the Right Shape

Because melting of metal powder is a very high temperature process, layers of parts built up can distort or change shape during buildup. This must be either measured or compensated for to ensure that the right part geometry gets built every time.

3. Speed & Productivity

On any one region of the part, the buildup speed is approx. 16 cubic mm per hour. Although several parts can be built in a single build run, this rate is too slow to allow 3D printing of metal parts to go beyond aerospace, defense and biomedical to automotive and general industrial applications.


4. Big Data

• AM is 100% digital data driven

• Huge data management requirements: – Part Design (1-100MB)

– Build Setup (1-10MB)

– In-Process Monitoring (100MB-1GB)

– In-Process Geometry Inspection (1-10 GB)

– Manufacturing Resource Planning (MRP) Systems

– Connection to Enterprise Resource Planning (ERP) Systems • PrintRite3D® generates 100GB per part • PrintRite3D® production data could be in 100 TeraByte to PetaByte range



Spa

PrintRite3D®: the goal is objective

evidence of compliance to design intent

Post-Process Quality Assurance

• AFTER THE FACT – defects have already occurred

• BACKWARDS – look for defects without chance of prevention

• ATTRIBUTES OF DEFECTS – based on detecting physical attributes of defects

• RESTRICTS PROCESS FLOW – inspect product condition only at a fixed point in time

In-Process Quality Assurance™

• BEFORE THE FACT – detect conditions leading to defects

• FORWARDS – look for conditions in time and takes action to avoid defective product

• ATTRIBUTES OF PROCESSES – based on detecting attributes of processes while they are occurring

• ASSISTS PROCESS FLOW – reduces PPQA inspection time and overall process time.


IPQA® is intrinsically superior to a “PPQA only” process flow which only sorts product

Sigma Labs’ Rapid Qualification Methodology


Classification

Algorithm

Logical

Model /

Database + = Rapid

Qualification

IN-PROCESS

Sensors

PROCESS

POST-PROCESS

Quantitative

Metallography &

Mechanical Properties

IN-PROCESS

Process Dynamical

Features

POST-PROCESS

Microstructural &

Mechanical Property

Features

Objective evidence of compliance to design intent is achieved only when in-process dynamical features and post-process features are linked

QUALITY In-Process Approach (aka, PrintRite3D® INSPECT™) NOT just process monitoring but linking in-process

data to post-process material properties and part performance

GEOMETRY Avoid X-ray CT and CMM if possible through use of

in-situ geometric measurements (aka, PrintRite3D® DEFORM™)

Must be fast and accurate enough

SPEED & PRODUCTIVITY Need at least 10X increase in speed without

compromising quality or geometry Need a manufacturing system that scales with

volume, not just a bigger printer in a bigger box!


PrintRite3D®

In-Process Metallurgical Properties

INSPECT™

Software that uses sensor data and establishes in-

process quality metrics or acceptance windows for each

metal or alloy during manufacturing process

development and verifies compliance to process

windows during the product / process life cycle.

In-Process Geometric Properties

DEFORM™

Software that uses sensor data and generates as-built geometrical model for each layer during the entire build cycle. It verifies compliance to print as well as allows for

process intervention.

In-Process Sensors & Hardware

SENSORPAK™

Sensors and hardware platform that collect true in-

process state variables documenting the process

function at each layer and the signature of a good part,

layer by layer.

Process Efficiency & Productivity

ANALYTICS™

Software and database that provides the ability to link all

critical (big) data over multiple builds, machines, fabrication sites, and over time to achieve maximum

benefit.

IPQA® Engineering

Consulting Services

Materials and Process Engineering services necessary apply the

PrintRite3D suite of tools to verify manufacturing process

development and assure product quality during the life

of the process.



Real-time Multi-sensors and Hardware Platform

Provides for layer-by-layer and

scan-by-scan quality

measurements and

assessments

Capable of measuring the true

in-process state variables

Comprises a set of off-axis and

on-axis in-process sensors

Observes process variations

Provides for reporting of

process anomalies

Copyright © 2014, Sigma Labs, Inc.


• When coupled with PrintRite3D® SENSORPAK™, generates part quality metrics and reports during serial production, eliminating post-manufacturing quality inspection.

• Provides manufacturing engineers with part quality metrics and report based on rigorous statistical analysis of manufacturing process data and permits non-suspect parts to by-pass traditional post-process inspection.

• Developed with

Real-time Quality Monitoring Software


Real-time Geometry Monitoring Software

• Layer-by-layer geometry measurement tool.

• Provides manufacturing engineers with the capability of comparison of ‘as-built’ to original digital CAD model ‘should be’.

• Includes optics, mechanical system and data path to image a two-dimensional melted powder.

• In development with

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Point Cloud of As-built Geometry


Measures (Inches)

Shoulder Width

Top hole ID

Top hole shoulder ID Base width Base ID

Center nub to top of bracket

Top hole centers

Engineering

Drawing 1.998 0.43 0.4383 3.7 0.218—0.226 -- 1.00

OCMM 1.997 0.4386 0.4556 3.76 0.222 1.34 1.0

CT* 2.01 0.44 -- 3.78 0.22 -- 1.0

DEFORM TBD 0.44 0.46 TBD TBD TBD TBD


Software that provides the ability to link all critical (big) data:

• over multiple builds, machines, fabrication sites, and;

• over time to achieve maximum benefit.

Provides for management and seamless access to all data over entire product lifecycle by integrating with current ERP / MRP systems

Big Data Software & Database


Materials and Process Engineering Services

• Assistance in applying and optimizing PrintRite3D® suite of tools

• Verify manufacturing process development.

• Assure product quality during the life of the process.

Sigma Labs provides the missing element, i.e., IPQMs™, that link to post process quality metrics, e.g., quantitative metallography or mechanical properties,

thus allowing IPQA® to enable rapid qualification & certification efforts.


AM Prototype Parts AM Serial Production

Process Control Functionality

Dri

ve

In-Process Data & Analysis

ANALYTICS™

Process Characterization

Process Validation

Process Qualification Bridge

America Makes In-Process Quality Assurance™ (IPQA®) for Laser Powder Bed Production of

Aerospace Components

GE Aviation (prime)

DARPA OM PHI & PHII Integrated Computational Material Engineering

Honeywell Aerospace (prime)

NIST In Process Monitoring for Laser Powder Bed Additive Manufacturing Systems

Edison Welding Institute (prime)


Benefits of Sigma Labs’ PrintRite3D® Software & Rapid Qualification Approach

• Provides 3rd Party Platform Independence – Machine Agnostic

• Establishes process window based on in-process dynamics

• Links in-process dynamics to material microstructure, mechanical properties, and part performance

• Provides objective evidence of compliance to design intent

• Shortens your overall qualification time

• Reduces qualification costs



www.sigmalabsinc.com

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