Processes, Inspections, and Reporting for Quality 3D Printing
How we use digital manufacturing and quality control processes to manufacture accurate parts consistently
Certifications ISO 9001:2015 | AS9100D | ITAR
Design for Additive Manufacturing Analysis
Our dedication to quality is apparent throughout the manufacturing process, and you'll experience it from your first interaction. When you submit a quote, you'll receive an analysis of your 3D printing design.
Our automated design for additive manufacturing analysis quickly identifies:
- Issues with part size (large or small)
- Gaps in material that are too small to form without collapsing
- Inaccessible surfaces to remove excess powder, remove supports, or apply surface finish treatment
- Text size for optimal text resolution
If you get one of these advisories, you will also notice that it includes a proposed solution to fix your model. With a single click, you can choose to accept the issue and proceed as-is or go back to redesign and resubmit your model.
Support from 3D Printing Experts
Discuss your design with a 3D printing applications engineer who can answer any manufacturability questions you might have. Common design review topics include optimizing for cost, feature location and spacing, and questions about finishing options.
Schedule a free virtual meeting today
Repeatability and Precision
Our mission is to deliver quality parts every time. To do that, we use clearly documented work standards and procedures. To minimize escapes, our team of skilled additive manufacturing technicians perform in-process quality checks on every unique geometry. Once the part is completed, our quality control experts take over to visually and dimensionally inspect the physical part, ensuring consistency with your 3D model (or print, if included).
Inspection Documentation for 3D-Printed Parts
All parts undergo a 100% visual inspection as well as part sampling of measurements to verify that basic dimensions meet quoted tolerances. With our AS9100-certified offerings—selective laser sintering (SLS), Multi Jet Fusion (MJF), and direct metal laser sintering (DMLS)—parts are sampled using AQL (Acceptable Quality Limit) level II as part of our manufacturing process.
If you need a report, we offer three different options, plus a comprehensive Build Report. Compare the benefits of each inspection report to see which is best suited for your project needs.
| Benefits | Measurements | Additional Features | Eligibility | Additional Lead Time | Sample Plan |
|---|---|---|---|---|---|
| Includes a dimensional report of requested features | Bubbled/CTQ dimensions if indicated, otherwise all toleranced dimensions | Formatted report with bubbled part image and result summary chart | All 3D printing technologies | Two business days or more depending on inspection requirements | One part per geometry, unless otherwise specified |
Additional Information: Upload a 2D drawing including requested inspection features. Reference Report is informational-only and is not pass/fail. Any features we are unable to measure will be stated in the Manufacturing Analysis of the part.
| Benefits | Measurements | Additional Features | Eligibility | Additional Lead Time | Sample Plan |
|---|---|---|---|---|---|
| Includes a pass/fail dimensional report of requested features | Bubbled/CTQ dimensions if indicated, otherwise all toleranced dimensions | Formatted report with bubbled part image and result summary chart | DMLS, SLS, MJF | Two business days or more depending on inspection requirements | One part per geometry, unless otherwise specified |
Additional Information: Upload a 2D drawing including requested inspection features. Dimensional Inspection Report is pass/fail per drawing tolerances. Drawing will be reviewed to ensure alignment with process capability. Any exceptions to the drawing (including features we are unable to measure) will be stated in the Manufacturing Analysis of the part.
| Benefits | Measurements | Additional Features | Eligibility | Additional Lead Time | Sample Plan |
|---|---|---|---|---|---|
| Includes a dimensional report of all features in AS9102 FAIR format | All dimensions and drawing notes | Full 3-page AS9102 document and matching bubbled drawing | DMLS, SLS, MJF | 2-5 business days or more depending on inspection requirements | One part per geometry |
Additional Information: Upload a 2D drawing that aligns with the requested 3d printing technology and material. Drawing will be reviewed to ensure alignment with process capability. Requests for redline or written acceptance of exceptions will be made at the time of quote if needed. Any exceptions to the drawing will be stated in the Manufacturing Analysis of the part. AS9102 is pass/fail and parts will be cleared for shipping once AS9102 report is signed and approved.
Reference Report
Typically, a Reference Report is used to if you want to get feedback on a part compared to any drawing you include but it cannot be used for pass/fail inspections. We provide a Reference Report for all of our 3D printing technologies.
Dimensional Inspection Report (DIR)
A DIR is a standard inspection tool used to compare parts to a drawing and provide a pass/fail result, which then requires customer feedback on any failures. There are no limits to the number of dimensions we measure, but any extra evaluation will increase work time and thus increase the lead time and price of your parts. While we use one part for the standard inspection, more parts can be inspected on request, adding lead time and cost.
Due to the nature of the material, we are not able to offer a DIR for stereolithography (SLA), PolyJet, and advanced photopolymer (AP) technologies.
Build Report
for SLS, MJF, and DMLS parts we offer a Build Report, which compiles your DIR with a comprehensive list of the information from the build process. These include, but are not limited to lot numbers, build numbers, over cycles, certificates of conformance, and certifications for outsources processes.
AS9102 First Article Inspection (FAI)
The AS9102 FAI is a more stringent report which validates the actual process used to make parts. Protolabs quality control will inspect 100% of dimensions provided on a 2D drawing, including GD&T. AS9102 is an industry standard format often required in the aerospace industry, but other fields can use it, too. It is significantly more intense from a completion standpoint.