Accelerated Mechanical Testing: Identifying Anisotropy and Inhomogeneity in Additive Manufacturing

At the 2025 Additive Manufacturing Users Group (AMUG) Conference, we showcased how Profilometry-based Indentation Plastometry (PIP) is accelerating AM part qualification. The method can be used to rapidly determine the mechanical properties of a part, without the need to print separate tensile coupons. By giving manufacturers the ability to test directly on printed components, PIP provides deeper insights than conventional methods. As a result, users can quickly and easily optimise build parameters, leading to stronger, more reliable components.

Overcoming Challenges in AM Parameter Optimisation

The ability to accurately assess local mechanical properties is critical for ensuring part performance and process optimisation within AM. PIP allows for efficient, localised mechanical testing without the need for extensive sample preparation. This technique is particularly useful for detecting inhomogeneities, identifying mechanical anisotropy, and evaluating how printing parameters influence material properties.

By offering a rapid and cost-effective alternative to traditional tensile testing, PIP can be implemented much earlier in the parameter development process, enabling manufacturers to optimise build parameters beyond density measurements alone. This was demonstrated in our collaboration with Additive Manufacturing Solutions, where PIP was used to rapidly assess the effects of different process variables on mechanical properties. By identifying trends in mechanical performance early in development, manufacturers can refine print parameters more efficiently, ensuring stronger and more reliable parts while reducing time and cost.

Case Studies: AM Part Quality

At AMUG 2025, we presented multiple case studies demonstrating the effectiveness of PIP across various stages of AM implementation. We explored how the PLX-Benchtop serves as a key characterisation tool throughout various stages of AM development, including through-process testing with Renishaw, anisotropy analysis with NASA, and inhomogeneity detection in final parts with Alloyed.

In our collaborative  case study with Renishaw, PIP tests were repeated on E8 tensile coupons throughout different stages of heat treatment and post-processing. By testing on the same coupons throughout processing, we could track the evolution of each tensile coupon’s mechanical properties, providing a clearer understanding of how each processing step influences final part performance.

With NASA, we investigated anisotropy in AM components by performing localised mechanical tests in different orientations. PIP enabled a detailed analysis of directional variations in mechanical properties, highlighting how printing parameters and thermal history contribute to anisotropy.

Our work with Alloyed concentrated on detecting inhomogeneities in final parts and correlating these variations to geometric features. PIP's high spatial resolution made it possible to map mechanical property distributions across complex geometries, providing insights that conventional tensile testing could not capture.

Enhancing AM Process Development with PIP

The ability to rapidly characterise mechanical properties at small scales is critical for improving AM part qualification and process optimisation. By integrating PIP testing into AM workflows, manufacturers gain deeper insights into anisotropy, inhomogeneity, and mechanical performance. This leads to higher-quality parts, more efficient process optimisation, and reduced production costs. PIP is not only accelerating testing but also providing additive manufacturing engineers with a powerful tool for achieving unmatched component performance.

Want to learn more about the PLX-Benchtop? Click here.

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Frequently Asked Questions

Why are anisotropy and inhomogeneity a challenge in additive manufacturing? 

Additive manufacturing offers great design freedom and material efficiency, but ensuring the mechanical integrity of 3D-printed components remains difficult, particularly because of anisotropy (directional variation in properties) and build inhomogeneity. Accurately assessing local mechanical properties is critical for ensuring part performance and optimising the process.

How does PIP testing help detect these issues? 

PIP allows efficient, localised mechanical testing without extensive sample preparation, making it well suited to detecting inhomogeneities, identifying mechanical anisotropy, and evaluating how printing parameters influence material properties. Its high spatial resolution maps property distributions across complex geometries, capturing variation that conventional tensile testing cannot.

How does PIP improve AM parameter development? 

As a rapid, cost-effective alternative to tensile testing, PIP can be implemented much earlier in parameter development, letting manufacturers optimise build parameters beyond density measurements alone. In a collaboration with Additive Manufacturing Solutions, PIP was used to rapidly assess how different process variables affect mechanical properties, helping refine print parameters more efficiently.

What did the case studies presented at AMUG 2025 show? 

Three collaborations demonstrated PIP across different stages of AM. With Renishaw, PIP tests were repeated on the same E8 coupons through stages of heat treatment and post-processing to track how properties evolved. With NASA, localised tests in different orientations analysed directional variation, or anisotropy. With Alloyed, PIP detected inhomogeneities in final parts and correlated them to geometric features.

What are the benefits of integrating PIP into AM workflows? 

Integrating PIP gives manufacturers deeper insight into anisotropy, inhomogeneity, and mechanical performance, the ability to test directly on printed parts rather than separate coupons, and earlier parameter optimisation. This leads to higher-quality parts, more efficient process optimisation, and reduced production costs.