Impulse Excitation for Additive Manufacturing: Defect Detection in 3D Prints

Author: Flowzy

Overview

Impulse excitation technology serves as a non-destructive testing method to identify defects in 3D-printed components. By applying controlled vibrations and analyzing resonant frequencies, manufacturers can detect structural weaknesses before parts reach customers.

The Problem: Hidden Defects in AM

Hidden defects in additive manufacturing commonly result from:

• Layer bonding failures: Incomplete fusion between layers
• Material contamination: Foreign particles affecting properties
• Thermal stress: Warping and residual stress accumulation
• Environmental conditions: Humidity and temperature variations

These microscopic flaws often escape traditional inspection methods, leading to field failures and reputational damage.

The Solution: Impulse Excitation

Impulse Excitation is a proven, non-destructive method that identifies defects by analyzing the resonant frequencies of a part. The technique measures mechanical properties including:

• Young’s modulus
• Shear modulus
• Damping characteristics

Key Advantages

Advantage	Description
Speed	Tests complete in seconds
Cost Efficiency	Catches defects early, preventing waste
Consistency	Ensures repeatable part performance
Non-Destructive	Parts remain fully usable after testing

Testing Workflow

The four-step process involves:

1. Preparation: Position part on support structure
2. Impulse application: Deliver controlled tap to excite vibrations
3. Data capture: Sensors record resonant response
4. Analysis: Software compares results against baseline measurements

Industry Applications

The technology serves sectors where component failure poses unacceptable risks:

• Aerospace: Structural brackets, turbine components
• Automotive: Performance parts, safety-critical components
• Medical devices: Implants, surgical instruments
• Industrial machinery: Custom tooling, replacement parts

Equipment

The GrindoSonic MK7 offers mobility, speed, and precision for diverse manufacturing environments, enabling both laboratory characterization and production-line quality control.