Design Metals for Additive Manufacturing Now

Enable the Novel Metal Structures of Tomorrow

Additive manufacturing (AM) stands for improving yield in industries like medical technology, aerospace or automotive. Inevitably, this trend to develop and improve 3D printing processes has a major impact on the rules of metallurgy and of what is possible when creating metals. New techniques mean new raw materials, alloys and analytical needs. Materials Researchers seek to characterize new architectures, determine product quality in this developing field, and to enable the novel, high-performing metal structures of tomorrow.

Researchers working in metal additive manufacturing, or metal 3D printing, face the challenge of characterizing the metal powder material, as the parts are created layer by layer from the metal powder, and of defining its quality – from the processing of the powder to its structure, properties, and performance in the final 3D printed parts. As the powder is the building block of additively manufactured parts, the size distribution of individual powder particles influences how it is compacted, and thus affects the density of the build. It also has an impact on the potential for defects that might only become visible later in the process. Therefore, verifying the absolute reliability of the final 3D printed parts is the foremost aim of researchers and engineers working in the field.

Microscopy Solutions for Metal Additive Manufacturing

Imagine being able to define the quality of the metal powder in each step of the material’s characterization, analyze the raw material for the powder, assess porosity and effectiveness of the sintering process in 2D and 3D or even investigate 3D morphology non-destructively? With Microscopy Solutions, you can exploit surface and roughness analysis techniques, apply high resolution imaging on sintered and unsintered regions, and benefit from multiple contrast modes during imaging. In addition, you will have the unique capability of studying finished parts non-destructively with X-ray microscopy using it as a research or a quality assurance tool.

  • Processing: Study the production of metal powders and understand the full process, from raw stock material to the final part, with X-ray Microscopy (XRM)
  • Structure: Observe and quantify the produced microstructures of the metal powder, like particle size distribution or examination of single powder particles, with Light Microscopy (LM) and Scanning Electron Microscopy (SEM)
  • Properties and Performance: Investigate or predict how an additively manufactured metal part will perform under real world conditions by conducting macroscopic and microscopic examinations of specimens using LM, SEM, and XRM. Conduct image processing and perform segmentation by using Software Solutions to determine relevant metallurgical information such as grain size, phase fractions, porosity, and layer thickness.

Study The Processing of Additively Manufactured Metal Parts

With X-ray Microscopy

Develop an efficient and effective process, and detect and characterize defects within metal AM parts reliably. In order to match the physical properties and the reliability of traditionally machined or formed parts, you want need to make sure your process produces parts with a density greater than 99.5%. However, the process parameters for fabrication can vary dramatically for different materials and shapes resulting in unwanted defects in the final part. Moreover, as the development of metal AM for mainstream production continues to grow, so will the need for improved understanding of the full process, from raw stock material to final part.

Non-destructive 3D Imaging of Feedstock Powder

  • Create 3D tomographic data sets at high resolution and contrast with minimal or no sample manipulation. Understand the interior structures of such parts better and introduce XRM into your lab.
  • Analyze complex AM parts easily with X-ray microscopes, which offer a unique architecture that allows easy collection of high resolution tomography information.
  • Investigate arbitrary locations providing you with a level of non-destructive analysis unavailable from conventional CT technologies by applying a smart software workflow. Use this new level of insight as a key to improving the overall process understanding for improved quality.

High-Resolution Tomography Data of 3D-Printed Flaws

Details of the 0.05” flaw in the Ti6Al4V sample. The upper right image is a 3D rendering of the flaw while the lower image shows a virtual cross section through the region. Features as small as ~30 μm (~0.0012”) are visible, demonstrating that the resolution would be sufficient to detect the smallest intended printed flaws of 0.002” and 0.005” if present.

Application Note

3D X-ray Microscopy Characterization of Additively Manufactured Parts

Click below to read the application note.


Observe and Quantify the Structure of Metal Powders

With Light Microscopy and Scanning Electron Microscopy

Whenever you are aiming to investigate fairly small powder particles of sizes ranging from a few micrometers to tens of microns in diameter rely on multi-modal microscopy techniques.

  • Use optical microscopes for quick powder sampling and reliable analysis of particle size distribution.
  • Examine batches or each individual particles and help engineers to better understand the built-in ingredients for additive manufacturing by using Scanning Electron Microscopes (SEM) that offer nanometer level resolution.

Particle Size Distribution Analysis

Light microscopes offer the possibility of quick powder sampling and reliable analysis of particle size distribution.

Individual Particle Analysis: Modularity, Satellites, Surface Contamination

Study Particles of Metal Powder for Additive Manufacturing with  Field Emission Scanning Electron Microscopy
Copper powder for AM or thermal spraying, showing modularity and satellites on the powder. SEM, Backscattered electron imaging (BSE), ZEISS SIGMA 300.
Study Metal Powder and Surface Contamination with Scanning Electron Microscopy
Surface of a Titanium alloy additively manufactured using selective laser melting, showing fully melted material and residual powder/surface contamination. Imaged using the HDBSD detector on ZEISS EVO 15. Sample courtesy of: TWI Ltd. UK.

Solutions Brochure

Additive Manufacturing - Improving Yield with Holistic Quality Inspection and Correlation

Click below to read the solutions brochure.


Investigate the Properties and Performance of Metals for Additive Manufacturing

With Mutli-modal Microscopy Solutions

Think what it would mean if you found a solution to minimize failures during additive manufacturing. You would be able to avoid the rejection of a small percentage of a batch of aluminum wire due to unexpected breakages or delamination of small regions of coating on a rolled steel. This would be a minor consequence. Or, alternatively, if the failure occurs in a major engineering application such as an oil rig, airplane, ship, or bridge, the failure can be catastrophic with long-lasting consequences. Once known, investigators can determine corrective actions to prevent or mitigate future failures.

No manufacturing or metal production system is perfect. Even with the most rigorous quality controls and thoroughly validated production methods, a percentage of component failure is always possible. However, to prevent or mitigate future failures, establish liability, or simply gain a better understanding of a system under test conditions, microscopy should be added as an essential step.

Driving the Industrializaton of Additive Manufacturing


Microscopy Solutions for Metal Additive Manufacturing

Discover the ZEISS Product and Software Portfolio

Light Microscopy (LM)

ZEISS Axio Imager, Axio Lab.A1, Axioscope, Axio Zoom.V16

Investigate Metals for Additive Manufacturing with Light Microscopy

Light Microscope, ZEISS LSM 900 for Materials

ZEISS LSM 900 for Materials

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ZEISS Axio Lab.A1

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ZEISS Axioscope

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ZEISS Axio Zoom.V16

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X-ray Microscopy (XRM)

ZEISS Xradia 600-series Versa, Xradia 800 Ultra Family

Investigate Metals for Additive Manufacturing with X-ray Microscopy

X-ray Microscope, ZEISS Xradia 620 Versa

ZEISS Xradia 600-series Versa

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ZEISS Xradia Ultra Family

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Scanning Electron Microscopy (SEM)

ZEISS EVO Family

Investigate Metals for Additive Manufacturing with Scanning Electron Microscopy

Scanning Electron Microscope, ZEISS EVO 15

ZEISS EVO Family

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Field Emission Electron Microscopy (FE-SEM)

ZEISS SIGMA Family

Investigate Metals for Additive Manufacturing with Field Emission Electron Microscopy

Field Emission Scanning Electron Microscope, ZEISS SIGMA 500

ZEISS SIGMA Family

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Software Solutions / Multi-modal Microscopy

ZEISS ZEN Core Modules, ZEN Connect, Atlas 5

Investigate Metals for Additive Manufacturing with Software Solutions

Software Solutions, ZEISS ZEN Core Modules

ZEISS ZEN Core Modules

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ZEISS ZEN Connect

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Questions? Get In Touch With Us.

Speak to our microscopy experts for metal additive manufacturing.

Get in touch with us to find out more about the benefits of ZEISS Microscopy Solutions for your metal additive manufacturing research, book a demo at our customer center, or get a quote. We are looking forward to hearing from you.

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