ASTM F3091/F3091M-14(2021)
(Specification)Standard Specification for Powder Bed Fusion of Plastic Materials
Standard Specification for Powder Bed Fusion of Plastic Materials
ABSTRACT
This specification applies to plastic parts that are created using powder bed fusion processes, including unfilled formulations and formulations containing fillers, functional additives (for example, flame retardant), and reinforcements or combinations thereof. The requirements are intended for use by manufacturers of plastic parts using powder bed fusion and for customers procuring such parts. The specification covers process classification, ordering information, materials (material specification and virgin powder), fabrication of test specimens, and material processing. Dimensional tolerances, source inspection, retest and rejection of parts, material and process certification, certification for parts, and identification marking of product are also specified, together with part packaging and package marking. A figure presents the specifications for mechanical testing of powder bed fusion polymer parts.
SCOPE
1.1 This specification describes a method for defining requirements and ensuring component integrity for plastic parts created using powder bed fusion processes. Materials include unfilled formulations and formulations containing fillers, functional additives (for example, flame retardant), and reinforcements or combinations thereof. Processes include all powder bed fusion processes as defined in Terminology F2792.
1.2 This specification is intended for use by manufacturers of plastic parts using powder bed fusion and for customers procuring such parts.
1.3 The values stated in either SI units or inch-pound units are to be regarded separately as standard. The values stated in each system are not necessarily exact equivalents; therefore, to ensure conformance with the standard, each system shall be used independently of the other, and values from the two systems shall not be combined.
1.4 This standard does not purport to address all of the safety concerns, if any, associated with its use. It is the responsibility of the user of this standard to establish appropriate safety, health, and environmental practices and determine the applicability of regulatory limitations prior to use.
1.5 This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
General Information
Relations
Standards Content (Sample)
This international standard was developed in accordance with internationally recognized principles on standardization established in the Decision on Principles for the
Development of International Standards, Guides and Recommendations issued by the World Trade Organization Technical Barriers to Trade (TBT) Committee.
Designation: F3091/F3091M −14 (Reapproved 2021)
Standard Specification for
Powder Bed Fusion of Plastic Materials
ThisstandardisissuedunderthefixeddesignationF3091/F3091M;thenumberimmediatelyfollowingthedesignationindicatestheyear
of original adoption or, in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval.
A superscript epsilon (´) indicates an editorial change since the last revision or reapproval.
1. Scope D6779 Classification System for and Basis of Specification
for Polyamide Molding and Extrusion Materials (PA)
1.1 This specification describes a method for defining re-
D6980 Test Method for Determination of Moisture in Plas-
quirements and ensuring component integrity for plastic parts
tics by Loss in Weight
created using powder bed fusion processes. Materials include
E11 Specification for Woven Wire Test Sieve Cloth and Test
unfilled formulations and formulations containing fillers, func-
Sieves
tional additives (for example, flame retardant), and reinforce-
F2792 Terminology for Additive Manufacturing Technolo-
ments or combinations thereof. Processes include all powder
gies (Withdrawn 2015)
bed fusion processes as defined in Terminology F2792.
2.2 ISO/ASTM Standard:
1.2 This specification is intended for use by manufacturers
ISO/ASTM 52921 Standard Terminology for Additive
of plastic parts using powder bed fusion and for customers
Manufacturing – Coordinate Systems and Test Method-
procuring such parts.
ologies
1.3 The values stated in either SI units or inch-pound units 2.3 ISO Standards:
ISO 527-1 Determination of tensile products – Part 1:
are to be regarded separately as standard. The values stated in
each system are not necessarily exact equivalents; therefore, to General principles
ISO 3310-1 Test Sieves – Technical Requirements and
ensure conformance with the standard, each system shall be
used independently of the other, and values from the two Testing – Part 1: Test Sieves of Metal Wire Cloth
ISO 9001 Quality management systems – Requirements
systems shall not be combined.
ISO 13485 Medical Devices – Quality Management System
1.4 This standard does not purport to address all of the
ISO 15512 Plastics – Determination of Water Content -
safety concerns, if any, associated with its use. It is the
Second Edition
responsibility of the user of this standard to establish appro-
2.4 Other Standards:
priate safety, health, and environmental practices and deter-
AS9100 Quality Systems – Aerospace – Model for Quality
mine the applicability of regulatory limitations prior to use.
Assurance in Design, Development, Production, Installa-
1.5 This international standard was developed in accor-
tion and Servicing
dance with internationally recognized principles on standard-
ASQC C1 Standard C1 Specification of General Require-
ization established in the Decision on Principles for the
ments for a Quality Program
Development of International Standards, Guides and Recom-
mendations issued by the World Trade Organization Technical
3. Terminology
Barriers to Trade (TBT) Committee.
3.1 Additional definitions are listed in Terminology F2792.
2. Referenced Documents
3.2 Definitions:
2.1 ASTM Standards:
3.2.1 batch processing, n—powder preparation and delivery
D638 Test Method for Tensile Properties of Plastics
process in which a powder batch is blended using specific
D4000 Classification System for Specifying Plastic Materi-
quantities of virgin and used powder for use as feedstock,
als
sometimes in quantities larger than the machine build volume
or feed region(s) or both.
This specification is under the jurisdiction of ASTM Committee F42 on
Additive Manufacturing Technologies and is the direct responsibility of Subcom-
mittee F42.05 on Materials and Processes. The last approved version of this historical standard is referenced on
Current edition approved Oct. 1, 2021. Published November 2021. Originally www.astm.org.
approved in 2014. Last previous edition approved in 2014 as F3091/F3091M-14. Available fromAmerican National Standards Institute (ANSI), 25 W. 43rd St.,
DOI: 10.1520/F3091_F3091M-14R21. 4th Floor, New York, NY 10036, http://www.ansi.org.
2 5
For referenced ASTM standards, visit the ASTM website, www.astm.org, or Available from SAE International (SAE), 400 Commonwealth Dr.,Warrendale,
contact ASTM Customer Service at service@astm.org. For Annual Book of ASTM PA 15096-0001, http://www.sae.org.
Standards volume information, refer to the standard’s Document Summary page on Available from American Society for Quality (ASQ), 600 N. Plankinton Ave.,
the ASTM website. Milwaukee, WI 53203, http://www.asq.org.
Copyright © ASTM International, 100 Barr Harbor Drive, PO Box C700, West Conshohocken, PA 19428-2959. United States
F3091/F3091M − 14 (2021)
3.2.2 build cycle, n—single cycle in which one or more 4. Process Classification
components are built up in layers in the process chamber of the
4.1 Class I—Most rigorous process classification intended
machine.
for use in producing the highest quality parts with the highest
degree of confidence through detailed traceability required in
3.2.3 build volume, n—total usable volume available in the
quality documents.
machine for building parts.
4.2 Class II—A rigorous process classification intended for
3.2.4 continuous feed processing, n—powder preparation
use in producing high-quality parts with less traceability than
and delivery process in which a powder batch is dynamically
Class I.
blendedinasteadystateprocesstodeliverfeedstockasneeded
to the powder bed. 4.3 Class III—A general process classification intended for
use as a guideline in processing quality parts using best
3.2.5 customer, n—entity that receives end use parts from a
practices with minimum traceability.
part manufacturer.
4.4 Specific class-dependent recommendations and require-
3.2.6 feed region, n—in batch processing, the lcoation(s) in
ments are described regarding fabrication of test specimens
the machine where feedstock is stored and from which a
(7.1), mechanical property testing (7.4.2, Table 1), powder
portion of the feedstock is repeatedly conveyed to the part bed
batch identification (8.5.4 – 8.5.6), multiple laser systems
during the build cycle.
(8.7.3.1), part certification (13.3 – 13.5) and quality program
3.2.7 feedstock, n—the bulk raw material supplied to the requirements (S3).Additional requirements may be negotiated
between the customer and part manufacturer.
additive manufacturing building process.
3.2.8 master bounding box, n—the orthogonally oriented
5. Part Ordering Information
minimum perimeter bounding box which encloses all of the
5.1 Orders for parts to this specification shall include the
parts in a single build.
following information:
5.1.1 Reference to this ASTM International standard, pro-
3.2.9 nesting, n—parts that are made in one build cycle and
are located such that their arbitrarily oriented minimum bound- cess classification (Section 4), materials classification (Section
6), material and process certification requirements, number of
ing boxes will overlap.
test specimens as needed (Section 7), post-processing require-
3.2.9.1 Discussion—For a definition of the arbitrarily ori-
ments (8.8), definition of general dimensional characteristics
ented minimum bounding boxes, see ISO/ASTM 52921.
and tolerance (Section 9), part marking requirements (Section
3.2.10 overflow region, n—the location(s) in the machine
14), packaging requirements (Section 15), digital product
where excess powder is stored during a build cycle.
definition (CAD model), customer purchase order number and
3.2.10.1 Discussion—Feedstock is usually conveyed to the
quantity in pieces.
powder bed in excess of the volume needed.
5.2 Orders for parts may include the following information:
3.2.11 part cake, n—powder remaining in the powder bed at 5.2.1 Engineering drawings, bill of materials, assembly
instructions, manufacturing plan and special engineering re-
the end of a build cycle surrounding the fabricated compo-
nents. quirements (Section 7).
3.2.12 part manufacturer, n—entity that processes materials
FIG. 1 Specifications for Mechanical Testing of Powder Bed Fu-
A
and produces parts using additive manufacturing equipment.
sion Polymer Parts
Specification Class I Class II Class III
3.2.13 powder batch, n—powderusedasfeedstockthatmay
Build certification A minimum of A minimum of No tension
be used powder, virgin powder or a blend of the two.
three XY or YX three ZX or ZY specimens
tension speci- tension speci- needed unless
3.2.14 powder lot, n—quantity of virgin powder produced
mens with at mens at the requested by
under traceable, controlled conditions from a single unifying
least one speci- edge of the mas- customer.
manufacturing process cycle and provided with source docu-
men above and ter bounding
below the build box. If the build
mentation as described in 6.2.2.
envelope and ZX height is less
3.2.14.1 Discussion—Source documentation is also referred
or ZY tension than 57 mm
specimens stag- [2.25 in.], use
to as a “certificate of conformance”, “factory certificate”, or
gered at edges instead two XZ
“certificate of analysis”.
of the master and two YZ
bounding box specimens out-
3.2.15 powder vendor, n—entity that supplies or distributes
such that all lay- side the build
B
virgin powder.
ers of the build envelope.
envelope fall
3.2.16 used powder, n—powder that has been processed in
within a tension
specimen gage
at least one previous build cycle.
length.
3.2.16.1 Discussion—Subcategories may include powder
A
For part orientation notation, see ISO/ASTM 52921. For multiple laser systems,
from the part cake, feed, and overflow region.
see 8.7.3.1.
B
ForTest Method D638 or ISO 527, subsized tension specimens may be used for
3.2.17 virgin powder, n—unused powder from a single
ZX or ZY samples for build heights less than 57 mm [2.25 in.].
powder lot.
F3091/F3091M − 14 (2021)
6. Materials 7.2 Direction-Independent Properties—Testspecimensused
to assess direction-independent properties may be built with
6.1 Material Specification—This specification is intended to
associated parts anywhere in the build at the part manufactur-
facilitate communication between part manufacturer and cus-
er’s discretion. Unless otherwise specified by the customer or
tomer and to establish a condition for acceptance. Material
otherwise stated in the specific test method to be used, a
composition of the part(s) shall be defined as the brand name
minimum of three test specimens per build shall be evaluated.
of the powder to be supplied by the powder vendor or in
The specimen may be aligned to any direction axis (X, Y,or Z)
accordance with a standard classification system. Required
chosen by the part manufacturer.
material properties of fabricated parts and test specimens and
test methods, if any, shall be stated in the order. For parts with
7.3 Nonmechanical Direction-Dependent Properties—Test
direction-dependent or direction-independent properties, the specimens used to assess nonmechanical, potentially direction-
specification of test specimens and directionality are addressed dependent properties such as electrical resistance shall be built
in 7.1 through 7.4. in a location deemed by the part manufacturer to be the least
6.1.1 Plastic materials and testing requirements may alter- favorable orientation within the master bounding box for
natively be specified by composition in accordance with measurement of the property in question. This would typically
Classification D4000. These standard classification systems be in the Z direction and on a surface of the master bounding
may be applied to virgin powder, powder batches, and feed-
box. Unless otherwise specified by the customer or otherwise
stock.UseofClassificationD4000isintendedtobeameansof specified in the specific test method to be used, a minimum of
identifying plastic materials and associated test methods used
three test specimens per build shall be evaluated.
to support fabrication of end items or parts. It is not intended
7.4 Mechanical Direction-Dependent Properties:
to be a method for selection of materials.
7.4.1 All Mechanical Property Testing Except Tension
6.1.2 Several nomenclature examples are listed. This listing
Testing—Test specimens other than tension testing specimens
is not meant to be complete or to be used as an endorsement of
used to assess mechanical properties such as flexural modulus,
any specific material or material composition.
impact strength, and shear modulus shall be built in a location
6.1.2.1 Unreinforced polyamide 12 powder—Classification
and direction deemed by the part manufacturer to be the least
D6779 PA0400 or PA0410.
favorable orientation within the master bounding box for
6.1.2.2 Polyamide 12 powder with 15 % by weight glass
measurement of the property in question. This would typically
spheres added—Classification D6779 PA0400 GE15 A00000.
be in the Z direction and on a surface of the master bounding
6.1.2.3 LS processed unfilled polyaryletherketone test part
box. Three test specimens per build shall be evaluated using
with a tensile strength at break of 90 MPa, tensile modulus of
Test Method D638 or ISO 527 unless otherwise specified by
4250 MPa, and elongation at break of 3 % (ISO 527-1)—
the customer or otherwise specified within a specific test
Classification D4000 PAEK0000 KD090 KN042 LD003.
method required for part acceptance. Unless otherwise
6.2 Virgin Powder:
specified, the specimen type, tensile strength and percent
6.2.1 The composition, particle size, particle size
elongation at break shall be recorded.
distribution, powder morphology, viscosity, thermal character-
7.4.2 Tension Testing—The number, orientation, and loca-
istics and bulk density shall be acceptable for the powder bed
tion of test specimens for evaluation of tensile mechanical
fusion process, as certified by the powder vendor before or at
properties are tabulated in Table 1. Every build containing
delivery.
Class I or Class II parts shall include test specimens as
6.2.2 Each powder lot shall be accompanied by documen-
described in Table 1.
tation to include, at a minimum, powder vendor name or
classification as in 6.1.1 or 6.1.2, material identification (in-
8. Material Processing
cluding a material safety data sheet(s) (SDS) and Chemical
8.1 Virgin powder shall be supplied with an accompanying
AbstractsService(CAS)registrynumber(s)),lotnumber,mean
certificateofconformancefromthepowdervendorandshallbe
particle size, particle size distribution, and rheological and
segregated based on virgin powder lot number in prepa
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