Application-driven methodology for new additive manufacturing materials development

Purpose - A structured customer-driven and integrative methodology to develop materials is described. The proposed methodology is aimed to drive analysis and prioritization of the multiple variables involved in a new application case for 3D printing, which involves the development of a new alumina-starch-based powder. Design/methodology/approach - The development of new powder mixture designed for 3D printing of refractory supports for metal casting moulds is presented. The quality function deployment (QFD) method was applied. Inputs for QFD analysis were found using total quality management tools. Using this approach, six process and material variables were considered to drive a prioritization analysis using a Plackett-Burman Design of Experiment (DOE) array. As performance parameter, compressive resistance was measured and assessed. Findings - QFD analysis delivered standardized procedures, irrelevant factors and target values for intermediate step parameters. Sintering parameters were found to be the most influencing over compressive resistance. Research limitations/implications - The methodology was based upon a materials development case for 3D printing. Practical implications - Knowing in advance the influence of every affecting factor of the process provides a closer control on variability of final part properties, which is a key issue to launch parts into industrial applications. Quality planning and documentation in advanced is the basis for all the quality system of the new additive manufacturing (AM) process to be created. Originality/value - Procedures for quality planning and control were proposed. This study, as methodological research, intends to introduce industrial engineering practices and quality management routines for AM material/process developers.