3D Printing Additive Manufacturing in Industry: Certification Ensures Quality

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With additively manufactured semi-finished products, the process industry reaches new heights. Thanks to compliance with stringent safety guidelines and certifications, innovative and legally secure applications emerge.

The advantages of additive manufacturing are diverse: increased flexibility, reduced downtime costs, and less dependence on supply chains. 3D printing enables the rapid production of spare parts on-site and on-demand, without having to wait long for deliveries. This shortens downtime caused by unexpected and costly failures and eliminates the need for high inventory levels. Another advantage: additively manufactured parts are characterized by precision and high quality. This technology allows for highly complex geometries and innovations in areas where safety and reliability are crucial.

3D Printing Dolutions for Industry

Since 2014, a company from Baden-Württemberg has specialized in additive manufacturing: Rosswag Engineering has already produced more than 100,000 components for various industrial applications. The SME from Pfinztal relies on metal 3D printing using the laser melting process (Laser Powder Bed Fusion/LPBF). Complex geometries and delicate structures can be realized effortlessly, which is often difficult or impossible with conventional methods. 3D printing also allows for combining multiple functions into a single component. This saves assembly time and costs. Elaborate casting and negative molds are not required, reducing time expenditure and enabling more efficient use of resources.

Rosswag Engineering uses metal 3D printing in the laser melting process to manufacture high-performance heat exchangers made of steel or nickel alloys. These heat exchangers are specifically designed for use at temperatures up to 1,000 degrees Celsius and with low pressure loss. They are particularly suitable for applications in high-temperature fuel cells (SOFC) as well as other high-temperature and hydrogen applications. Compared to conventional designs, these heat exchangers offer up to four times higher performance per cubic meter and require only one-twenty-fifth of the volume. Thanks to additive manufacturing, complex structures can be created that enable a larger surface area inside the heat exchangers – innovations that are unattainable with traditional methods.

The Entire Process Chain in View

It is clear: all components, whether additively or conventionally manufactured, must comply with the Pressure Equipment Directive (PED). Rosswag Engineering has been certified by TÜV SÜD as a semi-finished product manufacturer for additively manufactured components and produces various certified pressure equipment using the material 1.4404 (316L).

For certification, TÜV SÜD experts assess quality assurance along the entire process chain. The focus is on the powder used, the processes applied, and the personnel involved. They also check whether the data is traceable and whether it is suitable for the intended use.

Rosswag Engineering took the first step several years ago by becoming certified for the production of high-quality metal powder – as the first company in Germany. This is because high-quality components from additive manufacturing require premium powder material that must meet specific quality criteria.

The quality of a component significantly depends on the metal powder used. Chemical elements and physical properties influence the manufacturing parameters. Quality assurance becomes even more complex when manufacturers develop chemically tailored alloys for additive manufacturing to improve performance or weldability. Subsequently, the process parameters (e.g., laser power, laser speed) must be qualified for these alloys in combination with the machine type. However, this effort is necessary to ensure relevant processes and material requirements and to fully exploit the potential of the additive manufacturing process.

Reproducibility in Focus

Particularly for complex components in critical application areas, extensive expertise is required to align manufacturing processes and the corresponding process chain. The complexity of the overall process demands continuous monitoring of process parameters and material properties.

Another challenge: reproducibility. Even outwardly identical components can exhibit different properties. The position and orientation of the component in the build chamber of the manufacturing system during production also play a crucial role. Expertise in generating suitable support structures and the correct orientation in the build space is essential for reproducible material properties. Furthermore, software solutions can help avoid errors, even for manufacturing complex components. A vital prerequisite for meeting high-quality standards is experienced personnel. At Rosswag Engineering, one in ten of the approximately 200 employees is dedicated to quality assurance.

A Catalog of Standards and Regulations

The certification of additively manufactured semi-finished products is based on a variety of standards and regulations. The overarching guideline is the Pressure Equipment Directive DGRL/2014/68/EU, which establishes general safety requirements. Additionally, the standard DIN/TS 17026 plays a crucial role. This standard addresses additively manufactured pressure vessels and their components, covering aspects such as powder composition, proof of powder origin, and verification of mechanical properties through tensile and impact bending tests on test specimens. Parts of EN 13445-4, which deals with the manufacture of unfired pressure vessels, are also incorporated into the certification.

Each additive "printer" requires individual build chamber qualification. It must be demonstrated that the mechanical-technological properties are reproducible. The results of this testing contribute to the optimal placement of components to be printed during the manufacturing process. For certification, TÜV SÜD examined more than 100 test specimens using both destructive and non-destructive methods.

Certification Brings Legal Certainty

Against the backdrop of extensive and complex regulations, new questions about additive manufacturing often arise. TÜV SÜD experts bridge this gap: They bring decades of experience in materials and welding technology, which also flows into the development of the certification program.

With the TÜV SÜD certificate, Rosswag Engineering demonstrates compliance with the Pressure Equipment Directive. Customers can be confident that the additively manufactured components meet the required standards. The proven quality assurance is a significant competitive advantage: upon completion of a certification and testing program, companies are optimally positioned in the booming future market of additively manufactured pressure equipment.

*Gunther Kuhn is Head of Product Management at TÜV SÜD Industrie Service. Dr.-Ing. Gregor Graf is Head of Technology at Rosswag.