Carnegie Mellon University in Pittsburgh will lead Institute for Model-based Qualification & Certification of Additive Manufacturing (IMQCAM) aiming to improve computer models of 3D-printed – also called additively manufactured – metal parts and expand their utility in spaceflight applications. The institute will be co-led by Johns Hopkins University in Baltimore.

Metal parts 3D-printed are made from powdered metals, which are melted in specific ways and shaped into useful parts. Such parts could be useful for things like rocket engines – giving more flexibility to create new parts when designs change – or as part of a human outpost on the Moon, where bringing pre-fabricated parts would be expensive and limiting. However, efficient certification and use of such parts requires high-accuracy predictions of their characteristics.

"The internal structure of this type of part is much different than what's produced by any other method," said Tony Rollett, principal investigator for the institute and US Steel professor of metallurgical engineering and materials science at Carnegie Mellon University. “The institute will focus on creating the models NASA and others in industry would need to use these parts on a daily basis.”

Detailed computer models, known as digital twins, will allow engineers to understand the parts' capabilities and limitations – such as how much stress the parts can take before breaking. Such models will provide the predictability of part properties based on their processing that is key for certifying the parts for use. The institute will develop digital twins for 3D-printed parts made from spaceflight materials that are commonly used for 3D printing, as well as evaluating and modeling new materials.