What do you do if your 3D Printing engineer is struggling with quality control?

For improving quality need to do 2 tasks. 1. Make proper SOP or improve steps of current SOP as per standards for engineer.(basically to follow Standard operation to obtain same results each time ) 2. Need to check maintenance of machine.(wear and tear change accuracy of machine and gives diffrent results each time.)

Make sure that the expectations/requirements of the customer/product are suitable for the additive technology that's being used. It may not be the engineer's fault if he's been asked to make something that's not suited to AM. Give that engineer enough of a voice in the company that he can weigh in and say (ideally early on) whether it's feasible to produce the part using additive.

First we need to check what are the quality requirement in each face. According to that we need to plan the support design during 3D printing. [SLA type]

I would also check on the skill of engineer n 3D printer area is. added the check of process 3d printer could play a role in quality issues

If 3D printing engineer is struggling with quality control, consider the following steps: 1. Identify the root cause; 2. Provide training and support; 3. Standardize processes; 4. Equipment maintenance; 5. Material quality control; 6. Quality control checkpoints; 7. Collaboration and knowledge sharing; 8. Invest in quality control tools; 9. Customer feedback and communication; 10. Continuous improvement By addressing the root cause and implementing these measures, you can help 3D printing engineer to overcome quality control challenges and produce high-quality prints consistently.

The review process is critical as even a slight imbalance in the print bed during the material extrusion process can lead to dimensional inaccuracies. Hence, it is essential to meticulously review the current processes and procedures governing 3D printing operations to pinpoint any deficiencies or inefficiencies in quality control measures. Establishing standardized protocols is imperative to maintain consistency and reliability throughout the manufacturing process.

Don't underestimate the power of a documented workflow. A clearly defined process ensures consistency and reduces errors. Reviewing the process with your engineer can highlight areas for improvement, like implementing quality control checkpoints or standardizing printer settings for different materials.

I would also check on the temperature of the air in the area the printer is. added with the melting point of 3d printer could play a role in quality issues

Material handling is crucial. Beyond just using the right filament, proper storage is essential to prevent moisture absorption or degradation. Consider implementing a first-in, first-out (FIFO) system for filament to ensure you're using the freshest material possible.

It's useful to have a filament dryer, this helps with quality. Especially with something very hydroscopic like PVA, but also helps PLA.

If you really are a 3d printing company I would say, buy a better quality printer that does most of this itself. Having worked with ￡150 printers and ￡20,000 ones, there's far less issue with the expensive ones. The ￡50k Markforged printers will even scan the part as it goes and AI will feed back into the print to ensure better accuracy. So buy a better printer and skip the 3d print engineer - maybe?

Proper calibration of 3D printers is indeed essential for achieving consistently high-quality prints. You should also: 1. Develop a detailed calibration checklist that covers all necessary aspects, including print bed leveling, extruder alignment, and temperature settings. This ensures a systematic approach to calibration. 2. Incorporate regular calibration checks into your maintenance routine. Set reminders or schedules to ensure that calibration is performed at appropriate intervals, preventing any potential quality control issues. 3. Maintain records of calibration procedures and results for each printer. This documentation serves as a reference point for troubleshooting and ensures consistency in print quality over time.

Calibration is more than just setting the bed level. Regularly checking factors like extrusion rate and filament diameter can significantly improve print quality. Invest in calibration tools if necessary to ensure precise measurements.

Early communication is key! Encouraging collaboration between your design and engineering teams can identify potential printing challenges upfront. Designers can optimize models for printability, minimizing the need for excessive supports or minimizing features outside the printer's capabilities.

Its also possible that the 3d printer is too old. So if all the above fails you have to buy a new 3d printer! In this way you'll also have the necessary time to locate and fix the problem, if fixing is possible. But in my experience when a printer is done, it's not worth it fixing it.

As a quality control engineer its obvious that they must have enough knowledge about the whole process. so continuous learning and being updated with every process, technology, material, etc., is vey important. Apart from this, help them to find the root cause of the problem in each phase starting from design to post processing. Implement pre quality control measures in each phase such as designing, slicing, material selection, pre processing, printing, post processing, instrument calibration, etc. This would help your quality control engineer to achieve more quality parts.