5541 Demonstration of Novel Methods for Effective AM Process Qualification/Requalification

Honeywell performed a risk assessment to select the minor machine software change for the project.


Additive manufacturing (AM) machines and materials qualification are major barriers to broad AM adoption. Generating the requisite data and models requires significant resources to produce statistically significant data. This qualification process requires generating test coupons under a controlled process and testing and analysis of the resulting data. These processes are then “frozen” with no changes to key process variables allowed. Standard-based guidance does not exist for requirements when a process change is needed. This greatly inhibits the agility of AM processes to respond to changes in the technology or supply base, allowing only one path to implement change to a qualified process — a total requalification, which may cost more than $3M per machine/material combination and take several years.


The objective of this project is to develop an effective, streamlined process for requalifying laser powder bed fusion (LPBF) Ti-6Al-4V and any components manufactured from this material after the equipment has undergone a minor software change.

Technical Approach

Honeywell will review its current machine qualification plan for opportunities to significantly reduce the number of tests necessary to requalify a machine after a minor software change. This review will inform the development of a delta qualification test plan and associated build layout. Honeywell will then complete a baseline qualification per its standard baseline qualification process to allow for subsequent comparison to a reduced delta qualification. Once the baseline qualification process is complete, Honeywell will complete the reduced qualification test plan and builds developed for a minor software change. Mechanical property results from the test plan will be compared to the baseline qualification process and Joint Metal Additive Database Definition (JMADD) mechanical property results to determine equivalency. Finally, a candidate machine will receive an approved minor software update and the reduced qualification will be repeated. Mechanical property results will be compared to the previously acquired mechanical property results on the project and if all results align, the reduced qualification test plan will be considered acceptable for use.

Project Participants

Project Principal

Public Participants

  • U.S. Department of Defense

Project Summary

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