Results

The success rate for additive manufacturing parts to be printed correctly on the first attempt can vary significantly depending on factors like the complexity of the design, material used, printer calibration, and operator expertise. Failure rates typically range from 30% to 50%.

DigitalClone® is the only solution available today that combines additive manufacturing process-microstructure-fatigue modeling capabilities into an integrated SaaS that can be used by industry designers to rapidly optimize their print processes or designs for maximum fatigue life performance.

The client was looking to decrease variable operations and maintenance (O&M) costs as well as physically dangerous turbine climbs. We implemented predictive maintenance focused on the highest valued components, providing monthly updates of RUL predictions to define and fix assets with damage before they fail or cause secondary damage.

The DoD has stated that it seeks technologies to accelerate the adoption of additive manufacturing and one factor that has limited the progress is the lack of a reliable in-situation defect detection and correction capability that would enable the real-time monitoring of the layer-by-layer build process to ensure sufficient quality control.

Sentient has partnered with U.S. Army and Air Force to develop industry-first capabilities to monitor AM layer-by-layer print processes, detect defects, and autonomously correct flaws to ensure quality.