CEO and Principal Level III Consultant MR Aerospace Inspections and Consulting
Additive manufacturing (AM) continues to advance rapidly in aerospace applications, yet qualification, repeatability, and compliance remain critical barriers to scaling production. This presentation will examine the role of nondestructive testing (NDT)—specifically Digital Radiography (DR) and Computed Tomography (CT)—as essential tools for verifying AM part integrity and enabling certification for flight hardware.
Drawing from case studies in powder-bed fusion and investment casting for aerospace components, we will demonstrate how imaging technologies reveal critical discontinuities such as porosity, lack of fusion, and geometric deviations that may not be detected through conventional inspection methods. These examples will highlight both successes and lessons learned in applying ASTM E2737 and ASTM E2698 baselines, as well as integrating inspection data with design models to confirm dimensional accuracy and detect internal flaws.
In addition, the session will address evolving best practices for inspection in AM, including the application of probability-of-detection studies, the integration of CT datasets into process feedback loops, and alignment with OEM and Nadcap requirements for additive qualification. Attendees will gain insight into how NDT processes are being adapted for additive geometries that challenge traditional inspection methods, and how inspection data supports continuous improvement and production readiness.
By focusing on technical outcomes and standards-based practices, this presentation underscores that inspection is not only a compliance checkpoint, but also a critical enabler of process optimization and certification in aerospace additive manufacturing. Delegates will leave with practical knowledge they can apply when deploying inspection strategies to improve repeatability, reduce risk, and accelerate the transition from prototype to qualified aerospace hardware.
Learning Objectives:
Upon completion, participants will be able to describe inspection challenges unique to aerospace AM and identify how DR/CT imaging addresses discontinuities such as porosity, lack of fusion, and geometric deviations.
Upon completion, participants will be able to explain how ASTM E2737, ASTM E2698, and related standards are applied to additive manufacturing qualification and repeatability requirements.
Upon completion, participants will be able to demonstrate how inspection data can be integrated into process feedback loops to improve repeatability, reduce risk, and support aerospace certification.
