The Defense Advanced Research Projects Agency (DARPA) is spearheading a project poised to revolutionize the certification process for critical 3D-printed parts. This initiative aims to dramatically reduce the time and resources required to validate these components, paving the way for wider adoption of additive manufacturing in critical industries like the military.
The Challenge: Certifying 3D-Printed Parts
Currently, certifying a single 3D-printed part can take an average of 18 months, requiring the computational power of a supercomputer to predict its lifespan and potential failure points. This lengthy and resource-intensive process has been a major obstacle to the widespread adoption of 3D printing, particularly in sectors where reliability and safety are paramount. Each 3D-printed part possesses unique features and potential defects, even when produced on the same machine using identical materials. This variability necessitates rigorous evaluation to ensure structural integrity and performance.
DARPA’s Solution: Project SURGE
To address this challenge, DARPA has launched the Structures Uniquely Resolved to Guarantee Endurance (SURGE) program. This ambitious project aims to compress the evaluation time for 3D-printed parts from 18 months to just three days, with the added goal of simplifying the process so that it can be performed on a laptop computer.
Texas A&M University Takes the Lead
DARPA has awarded $1.6 million in funding to researchers at Texas A&M University to develop a system for rapidly assessing the quality and expected lifespan of 3D-printed components used by the military. The Texas A&M team will focus on integrating in-situ data with the underlying microstructural features formed during printing. This approach will bridge expertise in process monitoring, microstructure characterization, and property evaluation, paving the way for faster and more reliable deployment of additive-manufactured parts.
Key Components of the SURGE Program
The SURGE program encompasses several key components:
- Real-time Monitoring: Development of a sensor package that can be installed on commercial 3D printers to monitor the printing process in real time.
- AI-Driven Defect Detection: Creation of an AI-driven high-resolution defect-detection system capable of reading and combining data from multiple sources.
- Microstructure Characterization: Analyzing the microstructural features of 3D-printed parts to predict their mechanical properties and performance.
- Property Evaluation: Assessing the mechanical properties of 3D-printed parts to ensure they meet the required standards.
Impact and Benefits
The successful implementation of the SURGE program promises several significant benefits:
- Accelerated Part Production: Reducing certification time will enable faster production and deployment of critical parts.
- Cost Savings: Streamlining the certification process will save millions of dollars for the Department of Defense (DOD) and other industries.
- Wider Adoption of Additive Manufacturing: Faster and more reliable certification will encourage the adoption of 3D printing in critical applications.
- Enhanced Reliability: Improved defect detection and microstructure characterization will ensure the reliability and performance of 3D-printed parts.
Penn State’s Approach: Acoustic Sensors and Ultrasonic Microphones
Another team, led by Christopher Kube, associate professor of engineering science and mechanics in the Penn State College of Engineering, is working on a two-year, $1 million grant from DARPA’s SURGE program. This team is developing a method to detect, measure, and localize porosity defects inside 3D-printed metal parts during the printing process.
Instead of waiting until after printing to check for flaws, Kube’s team will develop acoustic sensors built into the printing platform and ultrasonic microphones to detect and measure pores during the print.
Intact Solutions: AI-Driven Pre-Qualified Design
Wisconsin software provider Intact Solutions has received $1.8 million from DARPA to develop software backed by generative AI that enables pre-qualified design of metal AM parts. The company’s software, Intact.Additive, aims to optimize the cost and time efficiencies of the manufacturing process by informing generative design with data from both virtual simulations and real-world experiments.
The Future of 3D Printing Certification
DARPA’s SURGE program and related initiatives represent a significant step forward in the effort to streamline and accelerate the certification of 3D-printed parts. By leveraging advanced sensor technology, artificial intelligence, and a deeper understanding of material microstructure, these projects are poised to unlock the full potential of additive manufacturing for critical applications in the military and beyond. The ability to rapidly and reliably certify 3D-printed parts will not only accelerate production and reduce costs but also enable the creation of innovative designs and materials that were previously impossible to manufacture.
