Quality control in additive manufacturing: A review of traditional and advanced techniques

Additive manufacturing has transformed the production of complex and tailored components in multiple industries, including aerospace, automotive, biomedical, and consumer products. Nonetheless, maintaining the quality and reliability of these components presents a significant challenge. This review paper examines the progress made in quality control methodologies specifically designed for additive manufacturing processes. Conventional quality assurance techniques, including dimensional measurement, visual assessment, and mechanical evaluations (such as tensile, compression, and impact testing), are essential for determining the quality of the final component. Nonetheless, these techniques might not adequately identify internal flaws. This review analyzes the increasing importance of non-destructive testing (NDT) methods, including ultrasonic testing, computed tomography (CT), and infrared thermography, in detecting internal defects such as porosity, cracks, and lack of fusion. The document examines the foundational principles of these NDT techniques, evaluates their benefits and drawbacks within the framework of additive manufacturing, and underscores the latest developments in their utilization. Additionally, the analysis highlights the critical role of in-process monitoring and real-time quality assurance techniques. These methods focus on identifying and rectifying flaws during the printing process, thereby reducing the likelihood of generating defective components. This detailed analysis offers an in-depth examination of the present advancements in additive manufacturing quality control, emphasizing the essential contributions of both conventional and innovative methods. By analyzing the strengths and limitations of these methods, researchers and industry professionals can create more robust and effective quality control strategies, ultimately resulting in the production of high-quality and reliable AM components.