Quality Control of a Laser Additive Manufactured Medical Implant by X-Ray Tomography

Quality control of laser additive manufactured medical implants is of interest, especially if nondestructive quality control can be performed on parts before implantation. X-ray micro-computed tomography (microCT or CT) can be used for defect/porosity analysis as well as for comparing the part surface with its computer-aided design (CAD) file. In both cases, the limited use of CT is partly due to the variation in scan types and the quality of scans that can occur. We present a simple method demonstrating the use of a light metal casting as a reference porosity sample, to confirm good CT image quality and to quantify minimum detectable pore size for the selected CT scan settings. This makes a good comparison for additive manufactured parts, since castings generally contain more porosity. A full part-to-CAD comparison shows how the part is compared with its CAD file, as a second-quality control. The accuracy of the CAD variance is given by the minimum detectable pore size. Finally, the part is sectioned and scanned at two higher resolution settings showing small porosity (10–50 μm diameter) present but well distributed, as expected.