Direct metal laser sintering (DMLS) is an established technology in metal additive manufacturing. This complex manufacturing process yields unique as-built material properties that influence mechanical performance and vary with different machine parameters. Part porosity and residual stresses, which lead to part failures, and grain structure, as it relates to mechanical properties and anisotropy of DMLS parts, require investigation for different print settings. This work presents results for density, residual stress, and microstructural inspections on designed test artifacts for the benchmarking of 3D metal printers. Results from printing artifacts on two separate DMLS printer models with default parameters show highly dense parts for both printers, with relative densities above 99.5%. Characterization of residual stress through cantilevered deflection specimens indicates similar resulting thermal stresses developed in both build processes, with deflection averages of 32.48% and 28.09% for the respective machines. Additionally, properties of the test artifact printed after adjusting default machine parameters for equal energy density are characterized.

Across all industries, material specifications are tightening beyond previously understood process capabilities. Slight shifts in material grade, microstructure, heat treatment, or alloy composition can significantly impact long term material integrity. This study examines the feasibility of noncontact, 100% inline magneto-inductive testing on materials and components to ensure material quality standards. To investigate the hypothesis that material grade, carbon content, density, and alloy composition can be accurately tested in real time during production, an experiment was conducted using magneto-inductive test instrumentation and an encircling coil. The results of the investigation confirmed that 100% of the material in a component could be thus tested, accurately, efficiently, and autonomously verifying that the specified material grade with the proper composition and properties had been used.