TO 34A-1-1 1.PDF

TO 34A-1-1

TECHNICAL MANUAL

ADDITIVE MANUFACTURING

QUALIFICATION OF

TECHNICIANS, MACHINES AND

FACILITIES

This manual supersedes TO 34A-1-1 dated 11 February 2022.

DISCLOSURE NOTICE - This information is furnished upon the condition that it will not be released to another nation without the specific au-thority of the Department of the Air Force of the United States, that it will be used for military purposes only, that individual or corporate rights originating in the information, whether patented or not, will be respected, that the recipient will report promptly to the United States, any known or suspected compromise, and that the information will be provided substantially the same degree of security afforded it by the De-partment of Defense of the United States. Also, regardless of any other markings on the document, it will not be downgraded or declassified without written approval of the originating United States agency.

DISTRIBUTION STATEMENT C - Distribution authorized to the Department of Defense and U.S. DoD contractors only (Critical Technology, Export Controlled) (17 June 2022). Other requests for this document shall be referred to 406 SCMS/GUEE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFLCMC/EZPT-MTO.

WARNING - This document contains technical data whose export is restricted by the Arms Export Control Act (Title 22, U.S.C., Sec 2751, et seq.) or the Export Administration Act of 1979, as amended, Title 50, U.S.C., App. 2401, et seq. Violations of these export laws are subject to severe criminal penalties. Disseminate in accordance with provisions of DoD Directive 5230.25.

HANDLING AND DESTRUCTION NOTICE - Comply with distribution statement and destroy by any method that will prevent disclosure of con-tents or reconstruction of the document.

Published Under Authority of the Secretary of the Air Force

17 JUNE 2022

Dates of issue for original and changed pages are:

Original . . . . . . . . 0 . . . . . . .17 June 2022

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 40, CONSISTING OF THE FOLLOWING:

Page *Change Page *Change Page *Change No. No. No. No. No. No.

Title A i - v vi Blank vii - ix x Blank xi xii Blank 1-1 - 1-6 2-1 - 2-13 2-14 Blank 3-1 - 3-4 Glossary 1 Glossary 2 Blank

TO 34A-1-1

LIST OF EFFECTIVE PAGES

A USAF

* Zero in this column indicates an original page.

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . v

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . v

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . vii

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . xi

1 ADDITIVE MANUFACTURING (AM) METHODS, GENERAL INFORMATION . . . . . . . . . . . . . . . .. . . . . 1-1

SECTION I AM METHODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1 AM METHODS, GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1.1 Introduction to Manufacturing Processes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1.1.1 Formative Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1.1.2 Subtractive Manufacturing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1.1.3 AM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1.1.3.1 Direct Metal Laser Melting (DMLM) Process Details . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-1

1.1.1.3.2 Fused Deposition Modeling (FDM) Process Details . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-2

SECTION II PERSONNEL TRAINING/QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3

1.2 TRAINING/QUALIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3

1.2.1 Training Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3

1.2.2 Training Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3

1.2.2.1 Formal Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-3

1.2.2.2 On-the Job Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

1.2.3 Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

1.2.3.1 Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

1.2.4 Requirement for Special Task Certification and Recurring Training . . . . . . . . . . . . . . . .. . . . . 1-4

1.2.4.1 Air Force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

SECTION III AM EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

1.3 AM EQUIPMENT OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

1.3.1 Procurement of AM Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-4

1.3.2 Allowance Standard (AS) 783 or Air Logistics Complex (ALC) Specific AS . . . . . . . . . .. . . . . 1-5

1.3.3 Purpose of Centrally Procured AM Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

1.3.4 Locally Purchased AM Equipment Authorized in AS 783 . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

1.3.5 Service Contracts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

SECTION IV PROCESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

1.4 PROCESS CONTROL OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

1.4.1 Reason for Controlling the Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

1.4.2 Scope of Process Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-5

1.4.2.1 Process Control Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6

1.4.3 Process Control Documentation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6

1.4.4 Establishing a Documentation Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6

SECTION V REPORTING NEW OR IMPROVED AM PROCESSES . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6

1.5 REPORTING AM PROCESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6 i

1.5.1 Need for Reporting New and Improved Processes . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6

1.5.2 Authority . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 1-6

2 METAL ADDITIVE MANUFACTURING (AM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1

2.1 OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1

2.1.1 Direct Metal Laser Melting (DMLM) General Information . . . . . . . . . . . . . . . . . . . . .. . . . . 2-1

2.1.2 Annual Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3 Metal Powder Hazards in the DMLM Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.1 Inhalation Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.2 Ingestion Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.3 Skin Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.4 Fire Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.4.1 Potential Fuel Sources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.5 Chemical Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.5.1 Aluminum Powders and Water Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.5.2 Titanium Powders and Nitrogen Reaction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-2

2.1.3.5.3 Acids and Bases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.5.4 Condensate and Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.5.5 Combustible Metal Powders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.6 Ignition Sources and Mitigation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.6.1 Hot Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.6.2 Electrostatic Discharge (ESD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.6.3 Static Dissipative Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.6.4 Fire Risk Reduction Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-3

2.1.3.7 PPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-4

2.1.3.8 Fire Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.3.9 Notifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.3.10 Dust Collection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.3.10.1 Dust Collection System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.3.10.2 Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.3.10.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.3.11 Materials for Passivation of Condensate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-5

2.1.4 Powder Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.4.1 Material Specific Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.4.2 Apparel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.4.3 Virgin vs Reuse Powder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.4.4 Reuse Increments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.4.5 Reuse Sieving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.4.6 Reuse Powder Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.5 Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.6 Facility Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-6

2.1.6.1 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.2 Climate Controlled Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.3 Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.4 Walls and Partitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.5 Ceilings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.6 Doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.7 Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.8 Floor Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.9 Floor Surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.10 Floor Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.11 Temperature and Humidity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.12 Air Exchanges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

2.1.6.13 Oxygen Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-7

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TABLE OF CONTENTS - CONTINUED

2.1.6.14 Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8

2.1.6.15 Utilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8

2.1.6.16 Electrical Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8

2.1.6.17 Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8

2.1.6.17.1 Dedicated Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8

2.1.6.17.2 Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-8

2.1.6.17.3 Standard Auxiliary Electrical Outlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9

2.1.6.18 Inert Gases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9

2.1.6.18.1 Argon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9

2.1.6.18.2 Nitrogen Inert Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9

2.1.6.18.3 Waste Gas Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-9

2.1.6.18.4 Direct Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10

2.1.6.18.5 Connection to an Internal Waste Air Extraction System . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10

2.1.6.18.6 Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10

2.1.6.18.7 Non-Climate Controlled Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10

2.1.6.19 Other Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10

2.1.6.19.1 Water Requirement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-10

2.1.6.19.2 Computer Work Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.7 Machine Qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.7.1 Approved Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.7.2 List of Qualified Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.7.3 Qualification Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.7.4 Qualification Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.8 Post-Processing Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.8.1 Part Marking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.8.2 Heat Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-11

2.1.8.3 Part Separation and Support Material Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.4 Band Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.5 Wire EDM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.6 Surface Enhancement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.7 Media Blast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.8 Abrasive Tumbling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.9 Shot Peening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.10 Sanding and Polishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.11 Finish Machining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.8.12 Geometry Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.9 Quality Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.9.1 Non-Conforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.9.2 Dimensional . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-12

2.1.9.3 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-13

2.1.9.4 Non-Destructive Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-13

2.1.9.5 Typical Anomalies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 2-13

3 POLYMER ADDITIVE MANUFACTURING (AM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1

3.1 FUSED DEPOSITION MODELING® (FDM) PRINTERS . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1

3.1.1 FDM® General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1

3.1.2 Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1

3.1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-1

3.1.4 Facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-2

3.1.4.1 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-2

3.1.4.2 Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3

3.1.4.3 Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3

3.1.5 Machine Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3

3.1.5.1 Approved Printers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3

TO 34A-1-1

iii

3.1.5.2 List of Qualified Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3

3.1.5.3 Machine Qualification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-3

3.1.5.4 Qualification Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-4

3.1.5.5 Requalification of the HP/AICS Package after Material Change . . . . . . . . . . . . . . . . . .. . . . . 3-4

3.1.6 Model Material Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-4

3.1.7 Post-Process Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-4

3.1.8 Quality Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-4

3.1.8.1 Non-Conforming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-4

3.1.8.2 Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . 3-4

GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Glossary 1

TO 34A-1-1

iv

LIST OF ILLUSTRATIONS

Number Title Page

1-1 Upskin, Downskin, and Core Regions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 1-2 1-2 Core Exposure Pattern Hatching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 1-2 1-3 Geometry Slices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 1-3 1-4 Single Slice Print Extrusion Path . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 1-3 2-1 EOS M 290 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 2-1 2-2 DMLM Print Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . 2-1

LIST OF TABLES

Number Title Page

1-1 Field Unit AM Training Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 2-1 DMLM Equipment List for Printing Qualified Metal Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 2-2 Typical Temperature and Humidity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-3 Typical Equipment Housed in Climate Controlled Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 2-4 Example (EOS M 290) Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-5 Example (EOS M 290) Argon Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 2-6 Example (EOS M 290) Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-7 Typical Equipment Housed in Non-Climate Controlled Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-8 Reasons to Requalify Metal AM Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 2-9 Anomalies Inherent to the DMLM Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 3-1 FDM Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3-2 Potential Safety Hazard Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-3 Example (Fortus 900mc/F900/450mc) Weight and Space Requirements . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-4 Example (Fortus 900mc/F900/450mc) Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 3-5 Example (Fortus 900mc/F900/450mc) Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-6 Example (Fortus 900mc/F900) Compressed Air Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 3-7 Major Sub-system Equipment Affecting Build Quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 v/(vi blank)

INTRODUCTION

1 PURPOSE.

Additive Manufacturing (AM) is the manufacturing process through which three-dimensional objects are created by building up layers of material. The two standard classes of AM materials covered in this technical order include:

• Polymers

• Metals

2 SCOPE.

This publication contains the concepts, process controls, and theory of AM methods and shall be used as a guide in develop-ment of AM procedures and manuals. AM procedures shall be detailed step-by-step instructions with illustrations so qualified technicians can perform the required process. In addition, this manual provides guidance in safety guidelines. When the guidelines of this manual conflict with details in a depot local process order, or a weapon system specific directive, the depot local process order or weapon system specific directive shall take precedence. This manual consist of the following chapters:

Chapter 1 Additive Manufacturing Methods, General Information Chapter 2 Metal Additive Manufacturing Chapter 3 Polymer Additive Manufacturing

3 ABBREVIATIONS.

All abbreviations used in this manual are shown in the list of abbreviations below. Standard abbreviations are in accordance with ASME Y14.38, Abbreviations and Acronyms for Use on Drawings and Related Documents.

°C degree Celsius °F degree Fahrenheit AF Air Force AF MTO Air Force Metals Technology Office AF RSO Air Force Rapid Sustainment Office AFI Air Force Instruction AFLCMC Air Force Life Cycle Management Center AFMCI Air Force Material Command Instruction AFMAN Air Force Manual AFTO Air Force Technical Order ALC Air Logistics Complex ALT Alternate AM Additive Manufacturing AP Attaching Parts AR As Required AS Allowance Standard ATTC Advanced Technology and Training Center AWB Airworthiness Bulletin CAD Computer-Aided Design CAGE Commercial and Government Entity CFE Contractor Furnished Equipment CNC Computer Numerical Control DLA Defense Logistics Agency DMLM Direct Metal Laser Melting vii

DoD Department of Defense EDM Electrical Discharge Machine ESD Electrostatic Discharge ESDS Electrostatic Discharge Sensitive ETIMS Enhanced Technical Information Management System FDM Fused Deposition Modeling GFE Government Furnished Equipment HAZMAT Hazardous Material HCI Hardness Critical Items HEPA High-Efficiency Particulate Air HVAC Heating Ventilation and Air Conditioning Hz Hertz I&S Interchangeability and Substitution IPB Illustrated Parts Breakdown JQS Job Qualification Standard kW kilowatt MAJCOM Major Command MIS Maintenance Information System mm millimeter MPL Maintenance Parts List MTO Metals Technology Office NDI Non-Destructive Inspection NFPA National Fire Protection Association NHA Next Higher Assembly NI Numerical Index OJT On-the Job Training OSHA Occupational Safety and Health Administration PAPR Powered Air Purifying Respirator PCAMS Process Control Automated Management System PN Part Number PPE Personal Protective Equipment PSI Pound-force per Square Inch PSIG Pound-force per Square Inch, Gauge RDI Reference Designator Index REF Reference RO Rapid Sustainment SCMS Supply Chain Management Squadron SD Static Dissipative SDS Safety Data Sheet SMR Source, Maintenance, and Recoverability SPO System Program Office TCTO Time Compliance Technical Order TO Technical Order UOC Usable on Code UPA Units Per Assembly V Volt viii

4 RELATED PUBLICATIONS.

NOTE

When searching Technical Order (TO) numbers in the Enhanced Technical Information Management System (ETIMS) catalog, please use the wildcard (*) after typing in the TO number. Many TOs are not available in paper format, (i.e., digital (WA-1) or Compact Disk (CD-1)). This ensures TOs in all media formats will populate the search.

The following publications contain information in support of this technical manual.

List of Related Publications

Number Title

ASME Y14.38 Abbreviations and Acronyms for Use on Drawings and Related Documents DODI 5330.03_AFI 33-395 Defense Logistics Agency (DLA) Document Services TO 00-5-1 AF Technical Order System TO 00-20-1 Aerospace Equipment Maintenance Inspection, Documentation, Policies, and Procedures TO 00-25-234 General Shop Practice Requirements for the Repair, Maintenance, and Test of Electrical

Equipment TO 34A-2-1 General Procedures and Process Controls and Metals Additive Manufacturing TO 34A-3-1 General Procedures and Process Controls and Polymers Additive Manufacturing TO 42B5-1-2 Gas Cylinders (Storage Type) Use, Handling, and Maintenance

5 RECORD OF APPLICABLE TIME COMPLIANCE TECHNICAL ORDERS (TCTOS).

List of Time Compliance Technical Orders

TCTO TCTO TCTO

Number Title Date

None

HARDNESS CRITICAL ITEMS (HCI).

The HCI symbol ( ) establishes special requirements limiting changes and substitutions and that the specific parts listed must be used to ensure hardness is not degraded.

If included, items with nuclear survivability requirements are marked with the HCI symbol ( ). All changes to, or proposed substitutions of, HCIs must be approved by the acquiring activity.

ELECTROSTATIC DISCHARGE SENSITIVE (ESDS) ITEMS.

All ESDS parts shall be handled in accordance with the ESDS device handling procedures in TO 00-25-234.

If included, items containing ESDS parts are marked with the ESDS symbol ( ).

8 IMPROVEMENT REPORTS.

Recommended changes to this manual shall be submitted in accordance with TO 00-5-1.

ix/(x blank)

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and/or chemical processes which may cause injury or death to personnel, or damage to equip-ment, if not properly followed. This safety summary includes general safety precautions and instructions that must be un-derstood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to per-forming any specific task, the WARNINGs, CAUTIONs, and NOTEs included in that task shall be reviewed and understood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are considered essential to protection of personnel (WARNING) or equipment (CAUTION). WARN- INGs and CAUTIONs immediately precede the step or procedure to which they apply. WARNINGs and CAUTIONs consist of four parts: heading (WARNING, CAUTION, or icon), a statement of the hazard, minimum precautions, and possible results if disregarded. NOTEs are used in this manual to highlight operating or maintenance procedures, practices, conditions, or statements which are not essential to protection of personnel or equipment. NOTEs may precede or follow the step or proce-dure, depending upon the information to be highlighted. The headings used and their definitions are as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc. Failure to comply could result in injury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc. Failure to comply could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition, or statement.

xi/(xii blank)

CHAPTER 1

ADDITIVE MANUFACTURING (AM) METHODS, GENERAL INFORMATION

SECTION I AM METHODS

1.1 AM METHODS, GENERAL INFORMATION.

1.1.1 Introduction to Manufacturing Processes. Manufacturing processes can be divided into one of the three following categories: Formative, Subtractive, and Additive.

1.1.1.1 Formative Manufacturing. Processes that shape a raw material (liquid or solid) into a final part through the use of tooling and molds include casting, molding, and forging among others. While the initial investment in dedicated tooling may be high, these processes are suitable for high volume production because they ultimately may result in low part cost and fast cycle times.

1.1.1.2 Subtractive Manufacturing. Processes that produce a part by removing material from stock. These processes in-clude machining, grinding, lathe-turning, and shearing among others. Subtractive manufacturing offers increased design flex-ibility over formative processes with minimal tooling, but it generally results in increased part costs and manufacturing cycle times.

1.1.1.3 AM. Processes that generate a part by fusing material together layer-by-layer, directly from dimensional electronic geometry data. While AM unit part cost is often higher, these processes are extremely flexible and can produce a part with minimal lead time and often zero tooling. While each AM process has its own unique limitations, there is no inherent penalty for geometry complexity and with the rapid advances in AM materials and processes, part costs and cycle times continue to improve. Approved methods are discussed below.

1.1.1.3.1 Direct Metal Laser Melting (DMLM) Process Details. DMLM is an additive manufacturing process that uses lasers to selectively melt ultra-thin layers of metal powder to build a three-dimensional object. Objects are built from a ste-reolithographic file generated from a Computer-Aided Design (CAD) data.

a. The DMLM process begins with a recoater blade spreading a thin layer of metal powder on the print bed. Next, a laser is used to create the cross-section layer of the object by completely melting powder particles. The print bed is then lowered by the height of one layer thickness and a recoater arm passes over the build plate applying another thin layer of powder. This process is repeated to create the next object layer. After all layers are printed, the excess, un-melted pow-der is brushed or suctioned away and can be recycled for future builds. During the print process, the build chamber is filled with an inert gas, usually argon, to prevent oxidation.

b. In this process, the print parameters vary for different portions of the part. The print software performs an analysis of the part and determines upskin, downskin, core, and contour regions (see Figure 1-1). The exposure pattern for the core section of the part is in the form of hatchings that are offset by an angle from one layer to another (see Figure 1-2).

The contour of the part, which forms the outer edge of the part, is usually exposed to lower power to provide better sur-face finish. The print parameters for upskin and downskin, which are the upper and lower surfaces respectively, could be different from the core region and are determined by the software. The print parameters used for the upskin and downskin regions could affect the surface quality of the printed part. Since the downskin region is not directly connected to the build plate or supports, it cannot easily transfer heat away from the part and retains heat during the print process. As a result, the downskin is usually exposed to lower heat to improve surface quality.

1-1

Figure 1-1. Upskin, Downskin, and Core Regions

Figure 1-2. Core Exposure Pattern Hatching

c. In most cases, upon completion of the print process and removal from the printer, all metal parts will undergo a stress relieving heat treatment process prior to removal from the build plate. At this point, parts are removed from the build plate using a band saw or a wire Electrical Discharge Machine (EDM) and can undergo any machining necessary to complete the manufacturing process. A second heat treatment procedure may be required at this point to create de-sired material characteristics.

1.1.1.3.2 Fused Deposition Modeling (FDM) Process Details. The FDM build process is an additive manufacturing process in which thermoplastic filament is heated to its melting point and extruded through a heated extrusion nozzle to pro-duce AM parts. This melting of filament requires the use of thermoplastic polymers and does not work with thermoset polymers. Three dimensional CAD geometry is used to generate a print file by slicing the part into layers as shown in Figure 1-3. Unlike DMLM, the FDM process does not create a fully dense part. Instead, the print head first traces the perimeter of each print layer with a bead of filament called a “contour” as shown in Figure 1-4. Next, the print head fills the interior of the cross section with “rasters.” Rasters vary in angle from one layer to the next for better adhesion and overall part strength.

While layers can be printed almost fully dense, there are often air gaps remaining between rasters due to part geometry. Some-times rasters will purposefully be printed with gaps to reduce the overall part weight and build time when strength is not a concern. Once a single cross-section layer is complete, the print head moves on to next slice increment layer and continues to print until the part has been completed layer by layer.

1-2

Figure 1-3. Geometry Slices

Figure 1-4. Single Slice Print Extrusion Path

SECTION II PERSONNEL TRAINING/QUALIFICATION

1.2 TRAINING/QUALIFICATION.

1.2.1 Training Introduction. All personnel require formal training and/or On-the-Job Training (OJT) prior to operating or performing maintenance on AM machines.

1.2.2 Training Requirements. Training requirements will be conducted using formal training and OJT. Formal training is further broken-down to include on-line training and in-residence training. All personnel shall be qualified, in writing and documented in accordance with Air Force Instruction (AFI) 36-2760, AFI 36-2650, AFI 21-101, Air Force Material Command Instruction (AFMCI) 21-100 and/or other local directives. Depot facilities may use requirements developed in accordance with local procedures, provided they meet the minimum requirements as defined in this general practice. See Table 1-1 for Field Unit training requirements.

1.2.2.1 Formal Training. Formal training shall be required for each process and type of equipment utilized in order to pro-duce airworthy components. The formal training requirement will include an AM on-line operator course and an AM in-residence operator course. Formal training conducted at a location other than Advanced Technology and Training Cen-ter (ATTC) shall be approved by the Air Force Life Cycle Management Center Metals Technology Office (AFLCMC/MTO) and reported to the AFLCMC/Rapid Sustainment Office (RO), prior to being accomplished.

1-3

a. On-line Operator Training: On-line courses are a prerequisite to in-residence training. Training will consist of familiar-ization and overview of AM technologies that have been qualified to produce airworthy components. Operator train-ing is a self-paced, module based course. Contact Air Force Rapid Sustainment Office (AF RSO) for on-line op-erator training location.

b. In-Residence Operator Training: Training will be conducted at an AF ATTC, or an AF MTO approved location. Opera-tors will receive machine and/or process specific training, which will qualify the operator to produce airworthy com-ponents on a qualified machine, utilizing qualified materials. Typical training at an ATTC can last up to ten (10) duty days for metal machine training and five (5) duty days for polymer machine training. Contact the AF RSO for addi-tional details and coordination of in-residence training.

1.2.2.2 On-the Job Training. Hands-on training for the practical application of the AM equipment and/or process shall be provided by the work center and shall be provided by personnel who have completed formal training and are qualified as OJT trainers. OJT alone will satisfy the training requirements for operations outside of those needing formal training per Table 1-1. All OJT shall be documented in accordance with AFI 36-2760, AFI 21-101, AFMCI 21-100 and/or other local directives. See Paragraph 1.2.3.1 for further guidance.

1.2.3 Qualification Requirements.

1.2.3.1 Personnel. Qualified AM machine operators shall be a Senior Airman (E-4) or higher, minimum 5 Skill level (or Civilian/Contractor equivalent). Document completion of formal training, qualification training and/or OJT on AF Form 797, Job Qualification Standard (JQS) Continuation Sheet (or electronic equivalent), Civilian Training Plan, or approved Mainte-nance Information System (MIS).

1.2.4 Requirement for Special Task Certification and Recurring Training.

1.2.4.1 Air Force. The weapon System Program Office (SPO), Major Command (MAJCOM), AF RSO, or Fabrication Flight Chief may determine special task certification and/or recurring training requirements for AM tasks. Document special task certification in accordance with AFIs 21-101, AFMCI 21-100, 36-2650, and/or local directives.

Table 1-1. Field Unit AM Training Requirements

Category Training Requirement

On-line Training In-Residence Training OJT Cat 1: Training Aids, Tooling-Fixtures/Jigs

X

Cat 2: Non-Structural, Non-Critical Vehicle*

X

Cat 3: Structural, Non-Critical Vehicle*

X X X

Cat 4: Critical Vehicle* X X X Cat 2A: Non-Structural, Non-Critical Aircraft*

X X X

Cat 3A: Structural, Non-Critical Aircraft*

X X X

Cat 4A: Critical Aircraft* X X X

* For specific applications that fall within each category, contact the cognizant engineering authority

SECTION III AM EQUIPMENT

1.3 AM EQUIPMENT OVERVIEW.

1.3.1 Procurement of AM Equipment. Procurement of AM Equipment. AFLCMC/RO will coordinate on the purchase of AM equipment (3D printers) costing more than $50,000 including equipment utilized in the process development, printing, and post-processing of AM printed components to ensure they align with larger Air Force goals of standardization, interoper-ability, repeatability, efficiency, networking, and quality control.

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1.3.1.1 AFLCMC/RO is the Air Force focal point to coordinate the enterprise AM approach. Air Force organizations may submit requests to AFLCMC/RO via Sharepoint at https://org2.eis.af.mil/sites/21761/am/_layouts/15/start.aspx#/ or by email to AFLCMC.RSO.workflow@us.af.mil. Questions may also be directed to AFLCMC/EZPT-MTO by email to AFLCMC.EZPT-MTO.MetalsOffice@us.af.mil.

1.3.2 Allowance Standard (AS) 783 or Air Logistics Complex (ALC) Specific AS. This document identifies the types and quantities of centrally procured, weapon system-specific, and special purpose AM support equipment authorized for both field and ALC AM organizations. The 404th Supply Chain Management Squadron (SCMS) manages the AS equipment accounts. AM machines and special purpose support equipment are not currently listed in an AS and are locally funded and purchased.

a. The Air Force Chief of Staff (AF/CC) requires the management of all AM printers regardless of cost, on accountable property records. AM/3D Printers with an acquisition cost below $50K will require the unit commander’s written approval to accompany the property record. AM/3D Printers with acquisition cost $50K or greater will require RSO oversight and approval.

b. Account for all AM printers, also known as 3-D printers, in Accountable Property System of Record (APSR) Defense Property Accountability System - Property Accountability (DPAS-PA) module in accordance with AFI 23-111, Manage-ment of Government Property in Possession of the Air Force and Department of Defense Instruction (DoDI) 5000.64, Accountability and Management of Department of Defense (DoD) Equipment and Other Accountable Property.

1.3.3 Purpose of Centrally Procured AM Equipment. Head Quarters United States Air Force directs the use of stan-dardized AM equipment and processes whenever possible and has assigned authority for this direction to the AFLCMC/RO.

During the acquisition process, new equipment is both laboratory and field-tested to ensure safety, deployability, sensitiv-ity, repeatability, and maintainability. The use of non-standard AM equipment must be coordinated through the cognizant en-gineering authority, SPO, AS 783 Manager, and/or the AFLCMC/RO.

1.3.4 Locally Purchased AM Equipment Authorized in AS 783. Equipment items for AM processing shall not be pur-chased locally without the knowledge and approval of the AFLCMC/RO and MAJCOM Functional Manager. Consumable support items and replacement parts may be purchased at any time without approval.

1.3.5 Service Contracts. AM equipment is intricate and sophisticated machinery that requires long term service contracts provided by the Original Equipment Manufacturer (OEM), or an OEM approved vendor, to enable the user to receive main-tenance and upkeep that is beyond the organization’s capabilities. Each unit must review the machine manufacturer’s spe-cific service contract requirements to determine the machine-specific requirements in order to manufacture and/or print parts which have been qualified and approved for AM production by the cognizant engineering authority for the aircraft, system, or equipment. Service contract requirements will be coordinated and funded by the owning organization, with the assistance of and reported to AFLCMC/RO.

SECTION IV PROCESS CONTROL

NOTE

Process control overview is discussed in this manual. Specific process control procedures are located in Technical Order (TO) 34A-2-1 and TO 34A-3-1.

1.4 PROCESS CONTROL OVERVIEW.

1.4.1 Reason for Controlling the Process. Process control is essential to achieving consistent and reliable results from AM building processes. A well-regimented AM process control program will remove variability and ensure stability in the printing process. A complete program will facilitate machine to machine conformance to deliver a stable process.

1.4.2 Scope of Process Control. All areas are interrelated and have to be tuned to each other to achieve quality prints. If any one of these requirements is altered, the final outcome of the process will change, regardless of the operator’s profi-ciency. All frequency requirements for method-specific process control checks are published in TO 34A-2-1 and TO 34A-3-1.

Process control is a general term used to encompass the actions and documentation required by established directives and logic.

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1.4.2.1 Process Control Areas. Areas that fall within the scope of process control are as follows:

• Training and the demonstrated practical skills of operators

• Environment

• Material controls

• Equipment controls (e.g., operational and performance capability or Test Measurement Diagnostic Equipment user calibration)

• Written instructions (i.e. Technical Orders)

• Adherence to written operating instructions (if required)

NOTE

Machine scheduled maintenance will be conducted per the applicable machine-specific owner’s manuals and/or technical orders, and documented per TO 34A-3-1 and TO 00-20-1

1.4.3 Process Control Documentation Requirements. Documentation of process controls are completed to verify con-formance to established requirements in the areas described above. These requirements may be documented through the use of automated products (e.g. Process Control Automated Management System (PCAMS)), and/or use of AFTO Form 244, AFTO Form 95.

a. Separate documentation shall be maintained for each AM method, machine, and material with established process con-trol requirements.

b. Process control requirements shall not be documented on the same form used to record machine maintenance. Docu-mentation of process controls shall be recorded on a separate form, or automated product, yet may be of the same type and/or series (e.g. PCAMS, AFTO Form 244, AFTO Form 95).

c. As a minimum, this documentation shall reflect each element of process control with respect to required time intervals between checks, date of accomplishment for each check, condition of element checked, corrective action taken (if re-quired), initials of the person performing test, serial number or identification number of the element tested, manu-facturer, lot or number if applicable, and date put into service.

d. Unless otherwise directed, only the most recent required documentation that provides a satisfactory history concerning equipment and materials needs to be maintained.

1.4.4…