• EOS Transparent System | © EOS
    3D Printing Software EOSTATE

    EOS Monitoring & Quality Assurance
    for Production with Additive Manufacturing

Additive Manufacturing Process Monitoring Flexible Quality Assurance for 3D Printer

3D printing software for monitoring and quality assurance. Binding standards are a must-have in practically every industry. Especially in series production, reliable production quality is indispensable. That’s why quality control and quality assurance systems are extremely important for metal 3D printing. The solution: EOSTATE.

 

EOSTATE is the modular solution for end-to-end monitoring of all production and quality-relevant data in industrial 3D printing.

Optimized user-friendliness – rapid work results

The 3D printing software EOSTATE is easy to learn: the user interface guides users intuitively through each step of the data analysis. This makes work easier, produces quick results and makes it easy even for non-specialists to evaluate the monitoring data.

Four modules, one goal: reliable AM series production without compromise

Our monitoring and quality assurance package EOSTATE consists of four modules that can be used either individually or in combination with one another. In this way, EOSTATE meets the needs of a wide variety of industries, such as the aerospace, orthopedic technology, contract manufacturing, turbine and engine construction and tool-making sectors.

What EOSTATE Monitoring Does The Software at a Glance

EOSTATE Base

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EOSTATE PowderBed

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EOSTATE MeltPool

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EOSTATE
Exposure OT

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EOSTATE Base monitors all production-relevant data of the 3D manufacturing system. It constantly checks the status and external production conditions with sensors. If a value deviates from a predefined range, production is stopped and the operator is notified.
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FORMIGA P 110 Touchscreen | © EOS
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After each layering and exposure phase, EOSTATE PowderBed records the powder bed and detects any irregularities, such as an incomplete powder layer, grooves or cavities. If there is a problem, the build process can be interrupted quickly.
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Powderbed Monitoring | © EOS
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EOSTATE MeltPool makes the complex melting process transparent with high-resolution data by capturing the light emissions of the melt pool with sensors. This tool is ideal for users who want to improve their research and process development or optimize their production methods.
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EOSTATE MeltPool Analysis | © EOS
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EOSTATE Exposure OT is the only solution in industrial 3D printing based on optical tomography. It features a combination of hardware and software that is optimally tailored to the requirements of the aerospace industry. In quality assurance, EOSTATE Exposure OT monitors the entire build process, regardless of the part size, which reduces the cost of non-destructive testing after the build process is complete.
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EOSTATE Exposure OT | © EOS

How EOSTATE Works Real-Time Monitoring for Industrial 3D Printing

Your Advantages Lower Costs Despite Extensive Quality Assurance

The cost of quality assurance is often significantly higher than the part costs themselves. EOSTATE can reduce or eliminate downstream test methods such as computed tomography measurements.

Significantly speed up series production and process development by collecting data

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Cost Reduction in Manufacturing

Shorter QA and Development Cycles
Monitor quality-relevant data directly during the build process

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Automated Monitoring

Real-Time Monitoring of All Relevant Data
Optimized research and development thanks to transparent data on all processes

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Accelerate Application Development

Digital Library of All Process Data
Traceable digital quality assurance for every part that you deliver

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Complete Documentation

Every Part Is Inspected

Success Story MTU Significant Savings in Quality Assurance 

With the goal of finding a specific testing procedure for 100 % monitoring and documentation of the AM process, the engine manufacturer MTU Aero Engines began developing optical tomography (OT) in 2013. Based on their work, EOSTATE Exposure OT was developed in collaboration with EOS.

MTU Aero Engines has now been using EOSTATE Exposure OT for years for process development and quality assurance in the additive series production of borescope bosses for Airbus A320neo engines. This has allowed them to completely eliminate any downstream quality assurance procedures. 

EOSTATE Exposure OT is able to determine when a part is not flawless. Because of this, we were able to completely dispense with subsequent X-ray and CT inspections in the series production of borescope bosses. Economically, this is a huge advantage.

Dr. Karl-Heinz Dusel | Head of Additive Manufacturing Technology | MTU Aero Engines

The four modules in detail  EOSTATE Monitoring for your individual requirements

Our DMLS systems are all equipped with EOSTATE Base out of the box. The software monitors all system-internal sensors and indicates whenever a quantity such as the oxygen concentration or laser power is not within the target range. The following factors are also monitored: laser and scanner status with automatic scanner self-calibration, cooling system, electrics including the power failure protection, position of the build platform, dosing system and collection containers, status of the air circulation system, process chamber and ambient atmosphere, as well as the temperature of the build platform. If any of these quantities deviate from a predefined corridor, the build process is stopped and the user is notified.

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Prevents unnecessary interruptions of the build process

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Saves resources and time

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Helps to achieve maximum availability for your production systems

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Quality report – documents the base state of the machine at any time

Another prerequisite for a stable build process in 3D printing is a uniform and complete coating of the build platform at every layer. The PowderBed module is the solution for monitoring the current powder bed. After each layering and exposure phase, an integrated camera takes a picture of the build area and identifies any irregularities, such as an incomplete powder layer, grooves or cavities. This reveals any uneven or incomplete layering steps. If there are any problems, the build process can quickly be stopped.

The EOSTATE plug-in optimizes the application, allowing the recordings to be exported as a video clip to the work computer.

Your Advantages With EOSTATE PowderBed

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Layer monitoring with integrated camera

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Option to export to the work computer as a video clip with the EOSTATE plug-in

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Inspect the current powder bed and browse through all previous layers

EOSTATE MeltPool provides high-resolution information about the melt pool dynamics, making it the ideal complement to Exposure OT. Using on-axis sensors integrated into the beam path, MeltPool measures the emissions of the melt pool, giving deeper insight into the 3D printing process. Various individually adjustable analysis parameters make it possible to evaluate the part quality. The features of MeltPool make it ideal for users who want to improve their research and development processes or optimize their production methods.

Your Advantages With EOSTATE MeltPool

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Automatic monitoring and analysis of the melt pool in real time

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Detailed information about the melt pool dynamics – ideal for research and development

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Deeper insight into the build process for process development

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Individual parameter analysis – an objective quality assessment

The high complexity of additively manufactured parts places special demands on quality assurance. Downstream testing methods such as X-ray or computed tomography (CT) quickly reach their limits. In many cases, testing becomes more expensive than the actual manufacturing – several times over.

Exposure OT is a unique and cost-efficient alternative: As the world’s first commercial testing solution based on optical tomography, Exposure OT enables non-destructive testing after the build process. Regardless of the part size, Exposure OT records and analyzes the quality-relevant 3D printing process data with a sCMOS industrial camera. The camera captures the entire build space and measures the quality-relevant heat emissions in real time. Exposure OT then generates a list of indicators for the user to evaluate. The analysis algorithm can be adapted to individual requirements, meaning that each user only receives the results that are relevant to them.

Exposure OT enables you to eliminate the high costs of downstream quality assurance procedures. Exposure OT is also a useful tool for application development: the data that it collects can decisively improve series production and process development. This significantly reduces the development times of new products.

Whitepaper: Correlation of In-Process Monitoring Data and Mechanical
Properties of Lattice Structures

English Whitepaper

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Your Advantages With EOSTATE Exposure OT

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Lower downstream quality assurance costs thanks to a comprehensive and automatic analysis during the build process

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Quicker time-to-market thanks to reduced development cycles with a digital library

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Full documentation and analysis of every layer of the build job

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Automatic evaluation according to individually selected analysis parameters

Do you have questions about the EOS software suite or another product? Contact us now!

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