DI-SESS-82500

Additive Manufacturing Process Control and Qualification Report

Documents the qualification and ongoing process control of additive manufacturing systems, including machine calibration, material certifications, process parameter validation, and operator qualifications for metal-based AM processes.

Approval DateAugust 18, 2025

AMSC NumberF10596

Preparing ActivityAF-11 (AFLCMC/ROD)

Project NumberSESS-2025-034

OPR—

DTIC ApplicableNo

GIDEP ApplicableNo

Limitation—

Applicable Forms—

Approval Limitation—

Form Version—

DID Formatfree_text

963C CompliantYes

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

Supersedes

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Description & Purpose

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Application & Interrelationship

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Use & Relationship

The Additive Manufacturing Process Control and Qualification Report (AM-PCQR) is a comprehensive technical report used to document the qualification and ongoing process control of additive manufacturing (AM) systems, specifically for metal-based AM processes such as Laser Powder Bed Fusion (LPBF) and Directed Energy Deposition (DED). This report serves to document that the contractor's AM process has been thoroughly validated, that process control measures are in place, and that operators are adequately qualified in accordance with relevant industry standards and applicable contractual requirements.

a. This DID identifies documentation of the necessary elements of AM process control, including machine calibration, material certifications, process parameter validation, equipment qualifications, and operator qualifications. Process control is especially critical for aerospace and defense applications where high reliability, precision, and conformance to specifications are essential.

b. This Data Item Description (DID) contains the format, content, and intended use information for the data deliverable resulting from the work task described in the solicitation.

Preparation Instructions

1Reference DocumentsThe applicable issue of the documents cited herein, including their approval dates and dates of any applicable amendments, notices, and revisions, shall be as specified in the contract. ISO/ASTM 52920: Additive manufacturing - Qualification principles - Requirements for industrial additive manufacturing processes and production sites ISO/ASTM 52926-1: Additive Manufacturing of Metals - Qualification principles - Part 1: General Qualification of Operators ISO/ASTM 52926-2: Additive Manufacturing of Metals - Qualification principles - Part 2: General Qualification of Operators for Powder Bed Fusion Laser (PBF-LB) ISO/ASTM 52926-4: Additive Manufacturing of Metals - Qualification principles - Part 4: General Qualification of Operators for Directed Energy Deposition Laser (DED-LB) ISO/ASTM 52930-2021: Additive manufacturing - Qualification principles - Installation, operation and performance (IQ/OQ/PQ) of PBF-LB equipment ISO/ASTM 52943-2: Additive Manufacturing for Aerospace - Process characteristics and performance - Part 2: Directed Energy Deposition using Wire and Arc (Copies of these documents are available from https://www.astm.org) MIL-STD-1587: Materials and Processes for Aerospace Systems (Copies of this document are available from https://assist.dla.mil) SAE AMS7003A: Laser Powder Bed Fusion Process SAE AMS7032: Machine Qualification for Fusion-Based Metal Additive Manufacturing SAE AS9131: Aerospace Series - Quality Management Systems - Nonconformity Data Definition and Documentation (Copies of these documents are available from https://www.sae.org/standards/) AWS D20.1/D20.1M: Specification for Fabrication of Metal Components using Additive Manufacturing (Copies of these documents are available from https://www.aws.org) NASA 6030: Additive Manufacturing Requirements for Spaceflight Systems NASA 6033: Additive Manufacturing Requirements for Equipment and Facility Control (Copies of these documents are available from https://standards.nasa.gov)

2FormatThe AM-PCQR shall be submitted in the contractor's format with the following exceptions:

2.1RevisionsA Table of Revisions shall follow the Table of Contents, with details of changes and the date of revision.

3ContentThe AM-PCQR shall include the following sections:

3.1Cover PageThe Cover Page shall include:

3.1.1Contractor's company name, logo, address, phone number and author(s)

3.1.2The AM system or process name under contractincluding the part number(s) and revision number as defined in the contract and on the engineering drawings.

3.1.3Location of AM systems or process under contract

3.1.4Title indicating that this is an "Additive Manufacturing Process Control and Qualification Report."

3.1.5A "Submitted For" sectioncontaining the National Stock Number (NSN) for the part, the contract number, the part number, and the serial number (SN) as applicable.

3.1.6Date of submission and document number

3.1.7A "Submitted To" sectionwith the name and address of the procurement office or contracting officer.

3.1.8A section with the signatures of the document preparer, Quality Assurance (QA) representative, and Defense Contract Management Agency (DCMA) representativewith dates indicating the test/inspection completion.

3.2Table of ContentsThe Table of Contents shall clearly list all major sections, subsections, appendices, and illustrations (e.g., tables, photos, graphs) with their corresponding page numbers.

3.3Revision History TableThis section shall include the following details:

3.3.1The base designation of the AM-PCQR (initial revision "-")

3.3.2Subsequent revision designations (e.g., "A," "B,")describing the specific changes made in each revision and the date they were implemented.

3.4Purpose of the ReportThis section shall clearly outline the purpose of the AM-PCQR, specifying how the document demonstrates the contractor's compliance with the AM process control requirements. This includes identifying the relevant standards that the contractor is using for their AM process(es), as well as any specific contractual requirements. It should also describe the key objectives, such as:

3.4.1Demonstrating that the AM system is qualified to meet the technical specifications of the contract

3.4.2Validating that all facilities, AM equipment, and operators are properly qualified, and the AM material created meets the performance requirements specified

3.4.3Outlining ongoing process control measures to ensure consistent quality in production

3.5Applicable DocumentsThis reference section lists the documents and standards that can be used to prepare the report. Any specific contract or TDP requirements related to the AM process shall also be addressed.

3.6Process Control System DescriptionA detailed description of the Additive Manufacturing Process Control System, including:

3.6.1The AM system (e.g., LPBF, DED-LB) and its specific configuration

3.6.2The key process parameters (e.g., laser power, scan speed, layer thickness)

3.6.3Machine calibration methods and results, including any relevant certification or verification of the machine's capabilities

3.6.4In-process monitoring and control techniques (e.g., build environmental control [temperature, atmosphere], powder flow monitoring, laser scanning system diagnostics)

3.6.5Process stability and repeatability data

3.6.6Software or process control systems used for monitoring and controlling the AM process

3.7Material Certification and TraceabilityThis section should include:

3.7.1Material certification for all powders, wire stock, or other consumables used in the AM process

3.7.2Material traceability documentation, showing compliance with TDP feedstock and consolidated material specifications

3.7.3Details of the material supplier's certification, including batch numbers, lot numbers, and test reports

3.7.4Compliance with the material standards set forth in the contract

3.8Operator Qualification and TrainingThis section should include:

3.8.1Proof of operator training and qualification under ISO/ASTM 52926-2 (for PBF-LB) or ISO/ASTM 52926-4 (for DED-LB) or AWS D20.1 or NASA 6033

3.8.2Training logs and certifications for each operator

3.8.3Documentation of operator qualifications to handle specific AM equipment, materials, and processes

3.8.4Documentation that operators are familiar with all required safety standards, procedures, and regulations

3.9Test and Qualification DataThis section shall present the results from qualification tests conducted on the AM system, including:

3.9.1Test build resultsPerformance data from qualification test builds, such as mechanical testing data (e.g. tension, compression, shear), microstructure analysis, part dimensional accuracy.

3.9.2Test data comparisonA comparison of the actual results against the specifications or performance criteria outlined in the TDP or relevant industry standards.

3.9.3Failure analysis (if applicable)Identification of any non-conformances, failure modes, or issues that arose during the qualification process and the corrective actions taken.

3.10Process Control Monitoring and PerformanceThis section shall document the:

3.10.1In-process monitoring resultsContinuous or periodic monitoring of the AM process during production.

3.10.2Control charts and metricsGraphical representations of key process data, such as laser power, scan speed, and build temperature; and correlation with process stability or material performance.

3.10.3Performance metricsKey performance indicators (KPIs) related to build quality, cycle time, and material efficiency.

3.10.4Process improvement effortsAny ongoing efforts to improve process control, such as the implementation of advanced sensors, software upgrades, or modified build strategies.

3.11Nonconformities and Corrective Actions

3.11.1A detailed account of any nonconformities encountered during the qualification or process control phases

3.11.2Use of the SAE AS9131 Nonconformity Form (or equivalent) to document the root cause analysis, corrective actions, and preventive actions taken to mitigate future issues

3.11.3Documentation of corrective actions, including requalification if necessary

3.12AppendicesThe AM-PCQR shall include the following appendices:

3.12.1Appendix A: Machine Calibration Reportsincluding calibration certificates and procedures used.

3.12.2Appendix B: Operator Qualification Certificatesfor all personnel involved in the AM process.

3.12.3Appendix C: Material Certification Documentationprovide a summary documentation that includes batch certificates and supplier test reports.

3.12.4Appendix D: Qualification Test Dataincluding test results, graphs, and performance analysis.

3.12.5Appendix E: Nonconformity and Corrective Action Recordsdocumenting any deviations and resolutions.

References

ASTM International https://www.astm.org

SAE Standards https://www.sae.org/standards/

AWS https://www.aws.org

NASA Technical Standards https://standards.nasa.gov

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