Evaluation of failure modes on AM-processes

Additive Manufacturing (AM) has become increasingly popular in recent years, particularly in the aerospace industry, but still has challenges like ensuring high-quality parts and a reproducible process. This contribution presents an evaluation of failure modes in additive manufacturing (AM) processes. The scope of the study includes an overview of challenges in AM such as multivariate interaction and quality assurance.
A model for a generic process failure mode and effect analysis (PFMEA) is developed and applied in an industrial context, specifically in the aerospace industry. Recommendations are also derived to improve the speed, reproducibility, and stability of AM processes, with the goal of achieving first-time-right production. The study includes the demonstration of proposed recommendations on an exemplary application using laser powder bed fusion (LPBF).