NADCAP Rolls Out New Aerospace Audit Framework for Additive Manufacturing
The Performance Review Institute's NADCAP program, a rigorous aerospace supplier audit standard, has expanded its auditing framework to encompass additive manufacturing processes, ensuring controlled production for critical components.
The NADCAP program, administered by the Performance Review Institute (PRI), has adapted its established audit framework for conventional manufacturing to address the unique challenges of additive manufacturing (AM) in the aerospace sector. Richard Freeman, Principal Staff Engineer at PRI, detailed the program's evolution at the 2025 AMA: Aerospace, Space and Defense conference.
Unlike traditional subtractive methods where finished parts can be thoroughly inspected, the integrity of AM components, particularly those made via Powder Bed Fusion (PBF), requires upstream process verification. NADCAP's approach focuses on auditing the control of personnel, equipment, and documentation to ensure consistent and trustworthy production. This mirrors NADCAP's existing audits for special processes like heat treatment and non-destructive testing.
NADCAP, established in 1990, aims to streamline supplier audits by creating a unified set of criteria agreed upon by major aerospace and defense original equipment manufacturers (OEMs). The program does not create new specifications but rather develops compliance questions based on existing international standards such as SAE, ISO, ASTM, and AWS.
New audit criteria are actively being developed. AC7131/3 for Laser Powder Bed Fusion of non-metallic materials is nearing publication, following a successful test audit. AC7131/4 for Fused Filament Fabrication has completed technical ballots and will undergo a test audit soon. Cold Spray AM is also under development for AC7131/5, with publication anticipated in early 2027.
Audits include a general checklist covering company information, order processing, and requirement flow-down. Specific AM considerations include powder management, gas control, personnel qualifications, and inspection protocols. For PBF, audits further scrutinize equipment capability, software control, build interruptions, key process variables, and post-processing steps like heat treatment or hot isostatic pressing. Findings to date have highlighted common issues in moisture and contamination control, operator training, key process variable documentation, and software control.
NADCAP's integration of AM into its aerospace audit framework is a significant step toward standardizing and ensuring the reliability of additively manufactured components for critical applications. This standardized approach, drawing from existing international specifications, builds confidence in AM technologies for OEMs and will accelerate their adoption in demanding sectors like aerospace and defense, where process control is paramount.
Edited by the news editor with AI from the original report — please refer to the original source.