the specifics of the test itself are 
reviewed and approved by the delegated Technical Authority. 


4.17 Qualification Testing 

[AMR-33]  All AM parts in Classes A1 through B2 shall be subject to a qualification test program 
that demonstrates that part performance and functionality meet the mission design requirements, life 
factors, and life-cycle capability, given the following stipulations: 

a. Parts for qualification testing are produced to a QPP. 

b. Any AM part that functions as part of a mechanism is subject to the qualification, design 
life verification, and acceptance testing defined by NASA-STD-5017, Design and Development 
Requirements for Mechanisms. 

c. The protoflight approach to qualification of hardware as defined in NASA-STD-5001 or 
JSC 65828, Structural Design Requirements and Factors of Safety for Spaceflight Hardware, which 
does not include a dedicated test article, is not considered applicable to AM hardware of Classes A1 
through B2, nor is the “no test” option for verification by analysis only. 

[Rationale:  Given the current maturity of the AM design process and the potential for 
unanticipated failure modes, the need for experimental evidence confirming the design performance 
of AM parts through a performance qualification test series exists.] 

Parts may be qualified individually (if applicable) as part of a subsystem qualification or as part of 
an overall system qualification. Qualification tests are recommended for AM parts of all classes. If 
direct qualification testing is not feasible for a part in Classes A1 through B2, then an alternative 
rationale for part qualification may be proposed in the PPP.  

The requirement for qualification testing is governed by the program or project structural design 
and verification requirements. The approval of the qualification test and the specifics of the test 
itself are reviewed and approved by the delegated Technical Authority. 

4.18 Part Acceptance 

 Part Acceptance, Class A and B Parts 

[AMR-34]  For Class A and B parts, data that are objective evidence of part conformance shall be a 
prerequisite for acceptance of the part by the CEO and made available to NASA upon request, 
including, but not limited to, information showing compliance to all part acceptance items listed in 
an approved PPP (see section 7.6 of this NASA Technical Standard). 

[Rationale:  Objective evidence of part conformance is necessary for the CEO to confirm 
acceptability of parts received.] 

Production engineering records should be retained for the life of the program. Records for program 
residual hardware should be delivered to the procuring authority as part of contract termination. 


AM part acceptance, in the majority of cases, is expected to be done by a party other than NASA. 
This NASA Technical Standard does not require a formal End item Data Package (EIDP) 
deliverable subject to review and approval by NASA or its program(s), although acquirers may 
stipulate otherwise by contract. 

 Part Acceptance, Class C Parts 

[AMR-35]  For Class C parts, a certificate of conformance (CoC) shall be a prerequisite for 
acceptance of the part by the CEO and made available to NASA upon request. 

[Rationale:  A manufacturer-issued CoC is a definitive statement that a delivered product meets all 
requirements and is used by the accepting authority as evidence of conformance, particularly in the 
absence of lot-specific or unit-specific quality verification inspection results or test data.] 

 QUALIFIED MATERIAL PROCESS (QMP) 

The QMP provides a validated, verified, and maintained record of AM process controls that 
provides assurance of process repeatability for the foundational elements of the AM process (i.e., 
feedstock material quality, machine controls, and post-processing controls). The use of a QMP, the 
associated Material Properties Suite (MPS), and first-article inspection results provide the basis for 
an AM production item’s material performance capability. The QMP and MPS provide quantifiable 
metrics used to monitor the repeatability of the process over time using results of material tests on 
witness specimens. A QMP is classified as either a QMP-A, QMP-B, or QMP-C, corresponding to 
the part classification per Figure 4 (i.e., A, B, or C) for which the QMP has been developed. A QMP 
can be used to produce parts of equal or lower classification (e.g., a QMP-A can be used for Class 
A, B, or C parts, but a QMP-B can only be used for Class B and C parts). 

The QMP method of process development and qualification requires that the AM machine 
parameter sets and conditions remain constant throughout the build. This means that a model pre-
processor does not alter process parameter settings or values based on a prediction of build state, 
nor does the machine use process feedback to alter the parameter set during the build. This does not 
imply a limit on the number of fixed parameters that are used to define a parameter set. A variety of 
fixed parameters consistently applied to model volumes or surfaces is expected (e.g., contour, fill, or 
“down-skin” parameters in a L-PBF process definition). This base assumption limits the scope of 
qualification testing and identifies an AM process that has a high likelihood of producing a quality 
part. 

Most importantly, the concept of the QMP is based on a fixed parameter set(s). Therefore, AM 
processes that alter the parameter set based on process feedback are currently out of scope for this 
NASA Technical Standard. Common examples of these adaptive AM processes include the typical 
implementation of EB-PBF and some DED processes that use feedback. The qualification approach 
for adaptive processes would differ because it adds the scope of qualifying the adaptive algorithm. 


Most aspects of this NASA Technical Standard may be applied to such processes, but these parts 
have to be produced under a “point design” philosophy, which means the part quality and material 
performance has to be explicitly determined for each part once a part production process is defined. 
In an adaptive AM process, a majority of the part quality burden is held at the part-centric QPP 
state. 

Requirements for defining a Candidate QMP are given in section 5.4 in this NASA Technical 
Standard. QMPs are associated with a specific AM machine serial number. For instances when 
multiple machines and processes are identical per sections 5.2 and 5.5.1, the identical machine's 
QMPs may be classified as Sub-QMPs and, as such, are subject to reduced qualification 
requirements per section 5.5.1 in this NASA Technical Standard. Once defined, the Candidate QMP 
is then qualified through material evaluation and capability demonstration to establish a QMP. 
Requirements to qualify the material process are given in section 5.5 in this NASA Technical 
Standard. Following qualification, QMPs are then associated with or “registered to” an MPS that 
is used to derive the material allowables and associated design values that are used to determine 
the suitability of the QMP for manufacturing of a given part design. The process for registering a 
QMP with a MPS is given in section 5.6 in this NASA Technical Standard. For processes using a 
QMP-C specification, minimums and commercial AM specifications may be used for qualification 
and properties data. Methodology for compliance with the requirements of this section will be 
documented in the AMCP (see section 4.2 of this NASA Technical Standard) by referencing the AM 
manufacturer’s internal documents and relevant sections therein and providing a brief description 
or summary of the content. The expectation is that the QMP requirements in section 5 of this NASA 
Technical Standard are implemented through an internal AM process specification from the CEO or 
AM part producer. 

5.1 Process Development  

This NASA Technical Standard does not define the path the user should take to prepare a candidate 
material process for qualification. The user is expected to have a thorough understanding of the 
process and high confidence that the candidate process will meet the requirements of the 
qualification process before beginning. The effort required to reach high confidence in a candidate 
process may be negligible for a known, stable AM machine platform with a defined machine setup 
and parameter settings. Conversely, if the candidate material process involves a new material on a 
new machine platform, then the development of material specifications and process parameters is 
likely to be an extensive effort on a scale many times that of the final qualification process. 

Figure 6, Overview of AM Production Activities and Sequence, provides an overview of the 
necessary activities to meet this NASA Technical Standard. The development phase of this flow is a 
prerequisite but is not controlled by the requirements of this NASA Technical Standard. These 
activities are essential to establish a reliable candidate material process. 

The QMP process should be considered a confirmation and record that the identified candidate 
material process is mature, stable, and achieves the intended AM material state. The QMP process 
is not an AM material development activity. 


The part producer will demonstrate which parameters, and interactions thereof, are critical to the 
process and which are not, and implement appropriate control plans for both. Statistically designed 
experiments (i.e., a design of experiment (DOE) approach) may be useful for this purpose. Each key 
process variable should be demonstrated to meet requirements throughout the process window (i.e., 
at the extremes of the parameter settings, considering tolerance) defined within the applicable 
specification. Those process variables that have a significant impact on requirements are identified 
as key process variables and become part of the fixed process. 

Figure 6—Overview of AM Production Activities and Sequence 

5.2 Unique QMPs, Minimum Control Categories 

[AMR-36]  Each AM machine used to fabricate hardware shall have at least one QMP for each 
unique combination of the following control categories that affect the material condition: 

a. Feedstock specification and associated controls per section 5.4.1 of this NASA Technical 
Standard. 

 b. Associated machine, build process controls, and restart procedures per section 5.4.2 of 
this NASA Technical Standard. 

 c. Post-processing requirements per section 5.4.3 of this NASA Technical Standard. 

[Rationale:  The QMP provides definition and control for foundational AM processes, enabling 
parts to be built with a process of verified material quality. These three parameter categories are 
fundamental to ensuring process repeatability.] 

Note:  AM machines may operate under the auspices of multiple unique QMPs if variations in 
controls or material post-processing exist. 


5.3 Configuration Management 

[AMR-37]  Each QMP shall be controlled by the QMS and subject to configuration control. 

[Rationale:  Maintaining QMP integrity is a foundational AM process control enabling parts to be 
built with a consistent process of verified material quality. QMP configuration control, as defined 
by the QMS, provides reassurance that any changes to factors that affect a machine’s ability to 
produce consistent material will be qualified and validated. Tracking of QMP revisions for process 
changes is critical to the fundamental concepts of material integrity and process control.]  

Individual QMPs are not expected or required to be explicitly referenced within the AMCP. 

5.4 Definition of a Candidate Material Process 

Before any candidate material process can be qualified, it must be adequately defined. As 
represented in Figure 2, the three required elements that define a candidate material process 
according to this NASA Technical Standard are (1) a feedstock specification, (2) control factors 
governing the AM process, and (3) requirements for post-AM processing. This section defines the 
variables, methodologies for their control, and minimum levels of characterization that must occur 
to define a candidate material process. Once a candidate material process is defined, it is then 
systematically evaluated for qualification as a QMP. 

 Feedstock  

 Virgin Feedstock Procurement 

[AMR-38]  Feedstock to be used for a Candidate QMP shall be controlled by industry standard 
specifications or configuration-controlled material specifications that levy requirements, including 
tolerances when applicable, to ensure consistent performance in the process and govern, at a 
minimum, the aspects of virgin feedstock production and procurement defined in Table 9, Virgin 
Powder Feedstock Controls, for powders; Table 10, Wire Feedstock Controls, for wire; Table 11, 
Filament Feedstock Controls, for filament; and Table 12, Liquid Feedstock Controls, for liquid 
feedstock. 

[Rationale:  Control of feedstock is essential to consistent performance of the AM  process. Each of 
these controls is specified to minimize the likelihood of potential process failures related to the 
feedstock.] 

Controls listed in the tables below that are not applicable to a specific process should be identified 
in the QMP. It is important to note that not all controls listed have governing industry standards. In 
these cases, the content of the feedstock material specification must be augmented to define the 
missing control factor. It may not be feasible to statistically describe some control factors; in such 
cases, these will need to be specified qualitatively. 


5.4.1.1.1 Metal and Thermoplastic Powder 

Table 9—Virgin Powder Feedstock Controls 
Powders 
a 
Requiring powder producers and distributors to operate under a QMS conforming to 
SAE AS9100, SAE AS9120, Quality Management Systems – Requirements for 
Aviation, Space, and Defense Distributors, or an equivalent approved by the CEO. 
b Specifying unambiguously the method of powder manufacture. 
c Specifying powder chemistry requirements, including acceptable methods of 
measurement and tolerance. 
d 
Specifying particle size distribution (PSD) requirements and the acceptable methods for 
powder sampling and determining the PSD, including explicit limits in weight percent on 
the quantity of coarse and fine particles outside the PSD range. 
e Specifying, at least qualitatively, the mean particle shape (powder morphology) and 
limits on satellite/agglomerated particles using standardized terminology/methodology.* 
f 
Controlling the blending of virgin powder heats/batches into powder lots by requiring 
that each blended powder heat/batch individually meets all requirements of the feedstock 
specification. 
g Prohibiting post-production additions to the powder lot for control of PSD or chemistry 
(doping). 
h Providing requirements for powder cleanliness and contamination control, including 
moisture content for sensitive materials. 
i Providing requirements for powder packaging, labeling, and environmental controls. 
j Specifying rheological (flow and spreading) behavior of the powder and associated 
method of verification. 
k 
Specifying a certificate of compliance be provided for all levied requirements along with 
identifiers for each powder heat and blended lot and the date(s) and location(s) of powder 
production. 
l Specifying powder crystallinity morphology control, such as solvent processing 
procedures and heat treatments, if applicable. 
* Description of powder morphology requirements should use standardized terminology to the 
greatest extent possible by following powder standards such as ASTM F1877, Standard Practice 
for Characterization of Particles, and ASTM B243, Standard Terminology of Powder Metallurgy. 


5.4.1.1.2 Metal Wire 

Table 10—Wire Feedstock Controls 
Wire 
a Requiring wire producers and distributors to operate under a QMS conforming to SAE 
AS9100, SAE AS9120, or an equivalent approved by the CEO. 
b Specifying unambiguously the method of wire manufacture, including rolling and 
drawing. 
c Specifying wire chemistry requirements, including acceptable methods of measurement 
and tolerance. 
d Specifying geometric constraints and length requirements, including explicit tolerance. 
e Specifying finish requirements, including explicit tolerance. 
f Specifying permissible method of joining both ends for repair or break during wire 
processing at the production facility. 
g Providing requirements for wire cleanliness and contamination control. 
h Providing requirements for wire winding packaging, labeling, and environmental 
controls. 
i Specifying a certificate of compliance be provided for all levied requirements along with 
identifiers for each wire lot and the date and location of wire production. 


5.4.1.1.3 Thermoplastic Filament 

Table 11—Filament Feedstock Control 
Filament 
a Requiring filament producers and distributors to operate under a QMS conforming to 
SAE AS9100, SAE AS9120, or an equivalent approved by the CEO. 
b Specifying unambiguously the method of filament manufacture. 
c Specifying filament chemistry requirements, including acceptable methods of 
measurement and tolerance. 
d Specifying geometric constraints and length requirements, including acceptable methods 
of measurement and tolerance. 
e Specifying moisture requirements, including acceptable methods of measurement and 
tolerance. 
f Specifying permissible method of joining both ends for repair or break during filament 
processing at the production facility, if applicable. 
g Providing requirements for filament cleanliness and contamination control. 
h Providing requirements for filament winding packaging, labeling, and environmental 
controls. 
i Providing batch monitoring requirements for differential scanning calorimetry. 
j Specifying a certificate of compliance be provided for all levied requirements along with 
identifiers for each filament lot and the date and location of filament production. 


5.4.1.1.4 Photopolymeric Thermoset Resin 

Table 12—Liquid Feedstock Controls 
Liquid 
a Requiring resin producers and distributors to operate under a QMS conforming to SAE 
AS9100, SAE AS9120, or an equivalent approved by the CEO. 
b Specifying unambiguously the method of liquid manufacture. 
c Specifying liquid chemistry requirements, including acceptable methods of measurement 
and tolerance. 
d Specifying liquid viscosity, including explicit tolerance. 
e Prohibiting post-production additions to the material lot for control of chemistry 
(doping). 
f Providing requirements for liquid cleanliness and contamination control. 
g Providing requirements for liquid packaging, labeling, and environmental controls. 
h Specifying a certificate of compliance be provided for all levied requirements along with 
identifiers for each material lot and the date and location of material production. 


 Feedstock Reuse Requirements