From Powder to Performance.

ZEISS 3D ManuFACT

ZEISS 3D ManuFACT

Holistic 3D-Manufacturing inspection for aviation, medical & automotive

The new reliability in Additive Manufacturing

3D printing processes – additive manufacturing – are becoming increasingly a part of the industrial production chain. Medical technology, aerospace, and automotive industries are leading the innovation and implementation of additive manufacturing.

The greatest challenge lies here in the verification of the 3D-printed parts’ absolute reliability.

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The new holistic, integrated inspection

ZEISS 3D ManuFACT offers the perfect inspection verification. Using this unique holistic inspection process for 3D manufacturing we apply the concentrated competence of all ZEISS technologies. This integrated process brings the most reliable knowledge and thus certainty about the reliability of 3D parts.

From powder to reliable parts

Powder & material characterization


Powder is the building block of additively manufactured parts. Size distribution of individual powder particles influences how the powder is compacted and affects the density of the build and possibility of defects visible later in the process. Light microscopes, scanning electron microscopes and x-ray computed tomography help to define the powder
quality.

In-process data analysis


via Additive Manufacturing machine supplier

Post-print heat treatment & part removal


Successful build requires various post-processing treatments to ensure dimensional accuracy and optimal material properties. After printing, the part is still attached to the build plate. It is then heat-treated and removed with wire EDM. To better understand the influence of those processes on final quality, a CMM or optical 3D scanner can be used.

Defects & inner structure inspection


The quality of powder and how it is spread during the build process might cause voids or material impurity to form in the structure. Inspecting the quality of the build with light microscopes or internal structures with high-resolution x-ray computed tomography helps to determine process parameters influence and faster define a possible path to achieve optimal settings.

Post-print material quality inspection


The additive manufacturing process, unlike classic manufacturing methods, requires powders to be melted during the build. Melt temperatures and process parameters greatly affect the crystallographic composition and, as a consequence, part properties.

Dimensional and surface quality inspection


Dimensional accuracy and surface finish are critical to ensure proper assembly and consistent mating across multiple parts. The surface finish can be analyzed with optical methods, and the internal surface is examined with x-ray computed tomography. Dimensional accuracy of the final part can be validated either with coordinate measuring machines, optical 3D Scanning or with x-ray computed tomography.

Process data statistics & analytics


Collection and analysis of data across the entire process chain with ZEISS PiWeb provides a deep understanding of how process changes might correlate with different dimensional and material properties. Clear visual representation and correlation of results across all process steps help to quickly and more efficiently develop printing strategies while increasing yield.


ZEISS Portfolio for Additive Manufacturing

ZEISS 3D ManuFACT features a selection of products from the ZEISS portfolio. This unique holistic inspection solution for additive manufacturing focuses on:
  • MATERIAL COMPOSITION ANALYSIS
  • POWDER ANALYSIS
  • POST-BUILD ANALYSIS INCLUDING
  • HEAT TREATMENT, PART REMOVAL, AND CLEANING
  • METALLOGRAPHIC ANALYSIS
  • DEFECT ANALYSIS
  • SURFACE METROLOGY – EXTERNAL AND INTERNAL
  • DIMENSIONAL METROLOGY – EXTERNAL AND INTERNAL

Scanning Electron Microscope (SEM)

High-performance SEM with EBSD enables micro structural crystallographic characterization and powder analysis.

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Professional grade SEM with EBSD enables micro structural crystallographic characterization and powder analysis.

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Light Microscope (LM)

High-resolution and high-speed optical profilometer for detailed surface analysis.

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Inverted optical microscope for material analysis and detailed inspection of build patterns and cross sections.

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With the digital microscope it is possible to view the sample from multiple directions while maintaining focus for speed and simplicity of use.

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X-ray Computed Tomography (X-ray CT)

High-resolution X-ray CT to support detail analysis of powders, surfaces, and structures with voxel size down to 70 nm.

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High accuracy X-ray CT to support dimensional verification and defect analysis of parts with complex internal and external structures.

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High-speed X-ray CT to support automated di-mensional verification and defect detection of mass production quantities.

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Coordinate Measuring Machine (CMM)

The compact shop floor CMM allows investigation of post-build processes, showing any influences on dimensional accuracy of finished parts.

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3D Scanning

The 3D scanner sensor offers a high measuring speed, quickly showing any post-build process influences on the dimensional accuracy of a finished part.

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Data Management

ZEISS PiWeb is a scalable IT solution for quality data management which helps you organize the information flow resulting from Industry 4.0.

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Do you want to know how to improve yield in additive manufacturing?

Get the brochure and find out how it works