METRIC/SI (ENGLISH)

NASA TECHNICAL STANDARD NASA-STD-6033

Office of the NASA Chief Engineer

Approved: 2021-04-21

ADDITIVE MANUFACTURING REQUIREMENTS

FOR EQUIPMENT AND FACILITY CONTROL

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DOCUMENT HISTORY LOG

Status Document Change Approval Date Description

Revision Number
Baseline 2021-04-21 Initial Release

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FOREWORD

This NASA Technical Standard is published by the National Aeronautics and Space
Administration (NASA) to provide uniform engineering and technical requirements for
processes, procedures, practices, and methods that have been endorsed as standard for NASA
programs and projects, including requirements for selection, application, and design criteria of an
item.

This NASA Technical Standard is approved for use by NASA Headquarters and NASA Centers
and Facilities, and applicable technical requirements may be cited in contract, program, and other
Agency documents. It may also apply to the Jet Propulsion Laboratory (a Federally Funded
Research and Development Center [FFRDC]), other contractors, recipients of grants and
cooperative agreements, and parties to other agreements only to the extent specified or
referenced in applicable contracts, grants, or agreements.

This NASA Technical Standard is an applicable document to NASA-STD-6030, Additive

Manufacturing Requirements for Spaceflight Systems, and implements the requirements for
control of additive manufacturing (AM) equipment, associated facilities, and training of
personnel, which are to be documented in an Equipment and Facility Control Plan (EFCP).
Qualification of the AM process on each AM machine is essential, just as is required in the
commonplace qualification of welding processes in aerospace practice. The methodology for
qualification of the AM process has been standardized by NASA-STD-6030.

Process qualification depends upon a known state of calibration and qualification of the AM
machine, as well as the quality of controls over the supporting facility (e.g., the storage and
handling of feedstock powder). Regardless of the level of automation, AM is a complex and
meticulous process requiring practitioners with proper education, experience, and skills to
achieve the expectations of quality for aerospace applications.

Requests for information should be submitted via “Feedback” at https://standards.nasa.gov.

Requests for changes to this NASA Technical Standard should be submitted via MSFC Form
4657, Change Request for a NASA Engineering Standard.

Original Signed By April 21, 2021

Ralph R. Roe, Jr. Approval Date

NASA Chief Engineer

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TABLE OF CONTENTS

SECTION PAGE

DOCUMENT HISTORY LOG .......................................................................................... 2

FOREWORD ....................................................................................................................... 3
TABLE OF CONTENTS .................................................................................................... 4
LIST OF APPENDICES ..................................................................................................... 5
LIST OF FIGURES ............................................................................................................. 6

1. SCOPE .................................................................................................................. 7
1.1 Purpose ................................................................................................................... 7
1.2 Applicability........................................................................................................... 7
1.3 Tailoring ................................................................................................................. 8
1.4 Summary of Methodology ..................................................................................... 8
1.4.1 Deliverables............................................................................................................ 11
1.4.2 Applicable Technologies ........................................................................................ 11

2. APPLICABLE DOCUMENTS ........................................................................... 12

2.1 General ................................................................................................................... 12
2.2 Government Documents ........................................................................................ 12
2.3 Non-Government Documents ................................................................................ 12
2.4 Order of Precedence............................................................................................... 12

3. ACRONYMS, ABBREVIATIONS, AND DEFINITIONS .............................. 13

3.1 Acronyms and Abbreviations ................................................................................ 13
3.2 Definitions ............................................................................................................. 13

4. GENERAL REQUIREMENTS .......................................................................... 16

4.1 Tailoring of this NASA Technical Standard’s Requirements ............................... 16
4.2 Equipment and Facility Control Plan..................................................................... 17
4.3 Feedstock Management ......................................................................................... 17
4.3.1 Feedstock Traceability ........................................................................................... 17
4.3.2 Feedstock Storage and Handling ........................................................................... 18
4.3.3 Material Exclusivity in AM Systems using Powder Feedstock ............................. 18
4.3.3.1 Powder or Liquid Feedstock Lot Control Requirements in AM Machines ........... 19
4.3.3.2 Wire Feedstock Lot Control Requirements in AM Machines ............................... 19
4.3.3.3 Cleaning Procedures for Removal of Residual Feedstock..................................... 20
4.3.4 Feedstock Blending at the AM Part Producer ....................................................... 20
4.3.5 Contamination and Foreign Object Debris Control ............................................... 20
4.4 Digital Thread ........................................................................................................ 21
4.4.1 Computer Security ................................................................................................. 21

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TABLE OF CONTENTS

SECTION PAGE

4.4.2 Records Retention .................................................................................................. 21

4.4.3 Sensitive Data ........................................................................................................ 21
4.5 Installation Controls ............................................................................................... 22
4.6 Operational Controls .............................................................................................. 23
4.6.1 Operational Procedures and Checklists ................................................................. 23
4.6.2 In Situ Monitoring ................................................................................................. 23
4.6.3 Configuration Management of AM Machines ....................................................... 24
4.6.4 Maintenance ........................................................................................................... 24
4.6.5 Minimum Maintenance .......................................................................................... 25
4.6.6 Associated Equipment ........................................................................................... 25
4.6.7 Calibration ............................................................................................................. 25
4.6.7.1 Calibration Schedules ............................................................................................ 25
4.6.7.2 Optical System Calibration .................................................................................... 26
4.6.7.3 Calibration Intervals .............................................................................................. 27
4.6.7.4 Calibration State .................................................................................................... 27
4.6.7.5 Calibration Nonconformance ................................................................................. 27
4.7 AM Machine Qualification .................................................................................... 28
4.7.1 AM Machine Qualification Status for Production ................................................. 29
4.7.2 Establishing Initial Qualification ........................................................................... 29
4.7.3 Reestablishing Qualification .................................................................................. 30
4.8 Operator Certification ............................................................................................ 30
4.8.1 Training Program ................................................................................................... 31

LIST OF APPENDICES
APPENDIX PAGE

A Requirements Compliance Matrix ....................................................................... 32

B Operator Training ................................................................................................. 42
C References ............................................................................................................ 45

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LIST OF FIGURES

FIGURE PAGE

1 Topical Outline for NASA-STD-6030 ................................................................. 9

2 Key Products and Processes for NASA-STD-6030 ............................................. 10
3 Symbol Legend for Key Products and Processes ................................................. 11

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ADDITIVE MANUFACTURING REQUIREMENTS

FOR EQUIPMENT AND FACILITY CONTROL

SCOPE

This NASA Technical Standard is directed toward equipment and facilities used to produce
additive manufacturing (AM) parts for NASA spacecraft systems, including, but not limited to,
crewed, non-crewed, robotic, launch vehicle, lander, and spacecraft program/project hardware
elements. Requirements in this NASA Technical Standard assume the AM facility is already
compliant with all applicable federal, state, or local laws regarding environmental, health, or
safety regulations. The requirements in this NASA Technical Standard respond to section 4.5 of
NASA-STD-6030, Additive Manufacturing Requirements for Spaceflight Systems.
Equipment and facilities used to produce AM parts for interfacing ground support equipment
(GSE) or test equipment are covered by the requirements of this NASA Technical Standard only
to the extent required to prevent damage to or contamination of spaceflight hardware.

1.1 Purpose

The purpose of this NASA Technical Standard is to define the minimum requirements for
equipment and facilities used for AM processes that are used for AM part production of
spaceflight systems, including, but not limited to, hardware used for spacecraft, launch vehicles,
in-space and extraterrestrial surface systems.

1.2 Applicability

This NASA Technical Standard is applicable to facilities operating under the auspices of NASA-
STD-6030 that are used to produce AM parts for spaceflight systems, including hardware used
for spacecraft and launch vehicles, and AM parts used to interface with spaceflight hardware or
other GSE. This NASA Technical Standard may also apply to AM parts used for NASA non-
crewed missions (e.g., robotic missions).

This NASA Technical Standard is approved for use by NASA Headquarters and NASA Centers
and facilities, and applicable technical requirements may be cited in contract, program, and other
Agency documents. It may also apply to the Jet Propulsion Laboratory (a Federally Funded
Research and Development Center [FFRDC]), other contractors, recipients of grants and
cooperative agreements, and parties to other agreements only to the extent specified or
referenced in applicable contracts, grants, or agreements.

Verifiable requirement statements are designated by the acronym “EFCR” (Equipment and
Facilities Control Requirement), numbered, and indicated by the word “shall”; this NASA
Technical Standard contains 31 requirements. Explanatory or guidance text and rationales for
requirements are indicated in italics beginning in section 4 of this NASA Technical Standard. To
facilitate requirements selection by NASA programs and projects, a Requirements Compliance
Matrix is provided in Appendix A.

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1.3 Tailoring

Refer to section 4.1 in this NASA Technical Standard.

1.4 Summary of Methodology

The focus of this NASA Technical Standard is to define minimum requirements for control of
AM equipment and facilities. These controls are defined and implemented by the AM part
producer through an Equipment and Facility Control Plan (EFCP) and approved by the cognizant
engineering organization (CEO), which is unique to the AM facility. This plan defines
procedures and work instructions for production operations (e.g., powder feedstock management,
contamination control, computer security, and the maintenance and calibration of AM machines).

This NASA Technical Standard requires certified operators based on an operator training and
certification program to ensure AM operations are executed by personnel with proper knowledge
of the AM process, all related equipment, procedural controls levied by qualified processes, and
engagement of the Quality Management System (QMS). This is considered foundational to the
qualification processes and methodologies of NASA-STD-6030 and are to be established prior to
hardware production.

Figure 1, Topical Outline for NASA-STD-6030; Figure 2, Key Products and Processes for
NASA-STD-6030; and Figure 3, Symbol Legend for Key Products and Processes, reproduced
from NASA-STD-6030, illustrate how the content of this NASA Technical Standard relates to
NASA-STD-6030. See NASA-STD-6030 for a detailed discussion of these figures.

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Figure 1—Topical Outline for NASA-STD-6030

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Figure 2—Key Products and Processes for NASA-STD-6030

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Figure 3—Symbol Legend for Key Products and Processes

Deliverables

This NASA Technical Standard outlines the EFCP as a discrete deliverable that will be created
by the CEO and/or part producer, referenced by the applicable Additive Manufacturing Control
Plan (AMCP), and made available to NASA for review.

Applicable Technologies

This NASA Technical Standard is designed to be applicable to facilities using mature materials
and technologies as described by section 1.4.2 of NASA-STD-6030.

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APPLICABLE DOCUMENTS

2.1 General

2.1.1 The documents listed in this section contain provisions that constitute requirements of
this NASA Technical Standard as cited in the text.

2.1.2 The latest issuances of cited documents apply unless specific versions are designated.

2.1.3 Non-use of a specifically designated version is approved by the delegated Technical

Authority.

2.1.4 Applicable documents may be accessed at https://standards.nasa.gov or

https://nodis3.gsfc.nasa.gov/main_lib.cfm.

2.1.5 References are provided in Appendix C.

2.2 Government Documents

National Aeronautics and Space Administration (NASA)

NASA-STD-6030 Additive Manufacturing Requirements for Spaceflight Systems

NPR 7120.5 NASA Space Flight Program and Project Management

Requirements
NPR 7120.8 NASA Research and Technology Program and Project
Management Requirements

2.3 Non-Government Documents

None.

2.4 Order of Precedence

2.4.1 The requirements and standard practices established in this NASA Technical Standard do
not supersede or waive existing requirements and standard practices found in other Agency
documentation or in applicable laws and regulations, unless a specific exemption has been
obtained by the Office of the NASA Chief Engineer.

2.4.2 Conflicts between this NASA Technical Standard and other requirements documents are
resolved by the delegated Technical Authority.

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ACRONYMS, ABBREVIATIONS, AND DEFINITIONS

3.1 Acronyms and Abbreviations

AM Additive Manufacturing/Additively Manufactured

AMCP Additive Manufacturing Control Plan
AMRR Additive Manufacturing Readiness Review
CEO Cognizant Engineering Organization
EFCP Equipment and Facility Control Plan
EFCR Equipment and Facilities Control Requirement
FFRDC Federally Funded Research and Development Center
ft Foot/Feet
GSE Ground Support Equipment
L-PBF Laser Powder Bed Fusion
m Meter(s)
M&P Materials and Processes
MPS Material Property Suite
MRB Material Review Board
NASA National Aeronautics and Space Administration
NDE Nondestructive Evaluation
NIST National Institute of Standards and Technology
NRRS NASA Records Retention Schedule
OEM Original Equipment Manufacturer
PBF Powder Bed Fusion
PCRD Process Control Reference Distribution
PPP Part Production Plan
Prod Production
QMP Qualified Material Process
QMS Quality Management System
QPP Qualified Part Process
Qual. Qualification
SI Système Internationale or metric system of measurement
SPC Statistical Process Control
STD Standard
Sub Subsequent

3.2 Definitions

Additive Manufacturing (AM): Process of joining materials to make parts from three-
dimensional model data, usually layer upon layer, as opposed to subtractive manufacturing and
formative manufacturing methodologies. Adj., additively manufactured.

Additive Manufacturing Control Plan (AMCP): Document describing the means of

conformance, the method of implementation, and the tailoring rationale for each requirement in
this NASA Technical Standard.

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Additive Manufacturing Part/Preform: Any part using an AM process to produce some

or all of the part material volume. For the purposes of this NASA Technical Standard, “part” and
“preform” can be used interchangeably.

Additive Manufacturing Part Producer: The entity using the AM process to produce a
part.

Additive Manufacturing Readiness Review (AMRR): An integrated engineering review

of the maturity of all manufacturing controls for an AM part to confirm that all necessary process
controls and production engineering are in place to produce a part that fully and reliably meets
the certified design state. At a minimum, the AMRR team includes individuals cognizant of the
part from the disciplines of design, structural assessment, materials, and processes, AM
production, and safety and mission assurance. A successful, documented AMRR demarcates the
production process of the part becoming a qualified part process (QPP).

Build/Build Cycle: A single, complete operation of the AM process to create objects.

Multiple objects are commonly created consecutively or concurrently during a build.

Build Area: The area in the build plane where the build process is controlled and
qualified to a qualified material process (QMP) per this NASA Technical Standard. The build
area may be defined smaller than the full reach of the energy source or print head if needed to
maintain the quality level of the build process.

Build File: A machine-readable, executable file that requires no further software to

execute the AM fabrication process.

Build Plane: Plane in which the build process takes place (i.e., the plane normal to the
direction of material addition). For laser powder bed fusion (L-PBF), vat polymerization, and
fused deposition modeling, the build plane is commonly fixed and the build platform is lowered
incrementally to create the build.

Build Platform: Solid material base upon which parts are built.

Build Record: Any record of the outcome of a production process, including, but not
limited to, those listed in the production engineering record, shop traveler, work authorization
order, etc.

Cognizant Engineering Organization: The organization responsible for

establishing/maintaining the certified design state of the AM hardware and delivering AM
hardware compliant with all levied requirements. The CEO will typically be a supplier to NASA,
a subcontractor, or NASA.

Configuration Management: Process for establishing and maintaining consistency of a

product's functional and physical characteristics, evaluating and authorizing any changes to those

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characteristics, and recording and documenting the characteristics and any changes to them to
verify compliance with the product’s configuration requirements throughout its life.

Digital Product Definition: The finalized digital model encompassing all relevant
drawings and process-specific information to generate a build file.

Digital Thread: The virtual medium in which data is stored and subsequently referenced
through a part's life cycle. This configuration-managed infrastructure contains and fingerprints
the digital references for a part from foundational process controls through part production
controls.

Material Property Suite (MPS): A maintained collection of AM material property

information specific to a material and condition that includes material test data, material
allowables and associated design values, and criteria needed to implement and maintain
statistical process control (SPC) for the AM process.

Mission: A major activity required to accomplish an Agency goal or to effectively

pursue a scientific, technological, or engineering opportunity directly related to an Agency goal.
Mission needs are independent of any particular system or technological solution.

Nonconformance: The state or situation of not fulfilling a requirement. A nonconforming

product, process, software, or material does not meet manufacturing specifications or design,
composition, or contractual requirements. Examples include, but are not limited to, failures,
discrepancies, defects, anomalies, and malfunctions.

Operator: Personnel involved directly in the production of AM parts, from manipulation

of the digital product definition in preparation for the AM build through the completion of the
build process.

Powder Bed Fusion (PBF): An AM process that uses a high-energy source to selectively
fuse, layer by layer, portions of a powder bed.

Powder Lot (also blended powder lot): A quantity of powder supplied by a certified
powder producer that was manufactured by the same process and equipment and blended
simultaneously. The blended powder lot may contain multiple heats of powder when all heats
independently meet the powder specification.

Production Engineering Record: A configuration-controlled document or electronic

record that defines and records the sequence of all major operations and their outcomes when
producing a part.

Qualified Material Process (QMP), Subsequent QMP (Sub-QMP): A qualified material

process that has the same feedstock specification and controls, AM build processes (e.g., the
same key process variables), and post-processing as an existing QMP. The commonality to the
existing process allows for reduced testing to establish a qualified process.

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Repair: An action performed on a nonconforming part to make it acceptable for the

intended use, which changes the material condition and/or results in the part not meeting all
requirements, requiring a waiver or similar.

Structure: All components and assemblies designed to sustain loads or pressures, provide
stiffness and stability, or provide support or containment.

Support Structure: Supplementary, sacrificial material built along with a part used to
anchor overhanging geometry, provide dimensional stability, and/or promote proper thermal
management during an AM build.

Surface Treatment: A broad range of industrial processes that alter the surface of a
manufactured item to achieve a certain property.

GENERAL REQUIREMENTS

4.1 Tailoring of this NASA Technical Standard’s Requirements

[EFCR-1] Tailoring of this NASA Technical Standard’s requirements in the EFCP shall be
formally documented as part of program or project requirements and approved by the responsible
program/project NASA Materials and Processes (M&P) organization, the responsible
project/program, and the delegated Technical Authority in accordance with NPR 7120.5, NASA
Space Flight Program and Project Management Requirements, or NPR 7120.8, NASA Research
and Technology Program and Project Management Requirements.

Tailoring includes using existing or previously developed contractor processes and standards as
a submittal of the various required plans. Otherwise, the tailoring of requirements may be
documented in the EFCP, per section 4 of this NASA Technical Standard, by providing the
means of conformance, the method of implementation, and the tailoring rationale for each
requirement identified here. When an EFCP has been approved by the responsible
CEO/program/project as an acceptable means of compliance with the technical requirements of
this NASA Technical Standard, the EFCP may be used for the implementation and verification of
AM requirements on the applicable program/project.

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4.2 Equipment and Facility Control Plan

[EFCR-2] Prior to approval of an AMCP created under the auspices of NASA-STD-6030, a

CEO-approved EFCP shall be developed and controlled by the QMS, addressing, at a minimum,
the means of conformance, the method of implementation, and the tailoring rationale for each
EFCR requirement in this NASA Technical Standard.

[Rationale: The EFCP provides for consistent definition and implementation of equipment and
facility controls necessary for reliable AM part production.]

The AM part producer is intended to develop and maintain the EFCP with the concurrence of the
CEO. The requirement for the EFCP may be met by leveraging existing documentation for
control of equipment and facilities if all the requirements of this section are addressed, all
documents are configuration controlled by the QMS, and the documents that make up the EFCP
are identified in the AMCP per NASA-STD-6030.

4.3 Feedstock Management

Proper control of feedstock is essential to safe and reliable AM processes. This section provides
requirements for storage and handling, material lot control in AM machines, and blending
operations.

Feedstock Traceability

[EFCR-3] Traceability of the feedstock materials and the certificate of compliance shall be
maintained throughout the lifecycle of the part.
[Rationale: Maintaining feedstock traceability is critical to tracking feedstock usage, life limits,
and special usage requirements, and enables resolution of nonconformances involving
feedstock.]

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Feedstock Storage and Handling

[EFCR-4] The EFCP shall specify policies and procedures controlling the storage and
handling of feedstock material, including, at a minimum, the following aspects:

Identification of the individual responsible for controlling access to feedstock and

tracking usage.

Health and safety hazards.

Fire hazards associated with feedstock.

Safety Data Sheets.

Material and lot number identification for every container.

Storage in area with controlled access and suitable environmental controls and
conditions (e.g., temperature and humidity control).

Control of opened, partially used feedstock containers.

Tracking of feedstock expiration date when applicable.

Control of contamination and feedstock cross-contamination.

Procedural implementation of feedstock reuse controls per section 6.6 of NASA-

STD-6030 required by the CEO-approved AMCP.

Disposal procedures.

[Rationale: Proper management of feedstock is essential to ensuring safety in the facility,

controlling raw materials for the process, and ensuring overall reliability of the AM process.]

Reuse of feedstock materials in AM processes used for NASA programs has to be controlled and
implemented through the applicable EFCP and addressed in the applicable MPS per section 6 of
NASA-STD-6030.

Material Exclusivity in AM Systems using Powder Feedstock

[EFCR-5] Each AM machine using powder feedstock shall be dedicated to a single material.

[Rationale: The presence of different materials within the machine presents an unacceptable
risk of cross-contamination of feedstock materials.]

Feedstock cross-contamination in powder-based systems presents a major risk due to the

difficulty in verifying system cleanliness after a material is removed from the system. As new AM

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systems are designed, some of these configurations will lend themselves more readily than others
to changing materials. For system configurations that allow for simplified material changes,
tailoring of this requirement will be necessary in the EFCP.

4.3.3.1 Powder or Liquid Feedstock Lot Control Requirements in AM Machines

[EFCR-6] The number of feedstock lots present in a powder- or liquid-based AM machine at

any given time shall be controlled based on maximum machine build volume:

Only one feedstock lot is allowed in AM machines with a build volume capacity less
than or equal to 0.05 m3 (1.75 ft3).

A maximum of two feedstock lots is allowed in AM machines with a build volume

capacity greater than 0.05 m3 (1.75 ft3).

[Rationale: Maintaining unique traceability in powder or liquid lots for AM parts is essential to
managing the scope of potential feedstock nonconformance. For small volume machines, the cost
and effort of maintaining a single feedstock lot in the machine are negligible and provide clear
containment bounds for a feedstock nonconformance. For larger volume machines, it is
acknowledged that limiting to a single feedstock lot may impede operation. The two-lot limitation
balances nonconformance risk against operational necessity.]

At changing of feedstock lots, this requirement intends a nominal cleaning of the AM machine
per section 4.3.3.3 of this NASA Technical Standard to remove the prior lot of material, but does
not intend a disruptive cleaning throughout the machine for small residuals of the prior powder
lot unless the prior lot was found to be nonconforming.

Note: For machines using two lots of feedstock material, the certificate of compliance for each
lot will need to be documented in the end item data package.

4.3.3.2 Wire Feedstock Lot Control Requirements in AM Machines

[EFCR-7] AM machines using wire feedstock shall be limited to a single feedstock lot present
in the machine at any time.

[Rationale: Maintaining unique traceability in wire lots for AM parts is essential to managing
the scope of potential feedstock nonconformance. Large-scale AM systems that require feedstock
reloading during a large build or systems with multiple heads must use the same feedstock lot
throughout the build process.]

Some operations (e.g., gradient materials) may require multiple alloys. In that case, each alloy
has to be controlled in the same manner as the individual alloy processes.

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4.3.3.3 Cleaning Procedures for Removal of Residual Feedstock

[EFCR-8] Each AM machine building Class A or B hardware per NASA-STD-6030 shall

have documented procedures for cleaning out residual feedstock and evaluating cleanliness,
which are used prior to introducing new material lots per the material exclusivity requirements of
section 4.3.3 of this NASA Technical Standard, or when thorough cleanouts associated with
removing nonconforming lots or material changover are required.

[Rationale: Cross-contamination of powder lots or different materials poses a risk to material

quality and tracability.]

AM machines should be cleaned after the removal of remnants of an old powder lot and before a
new lot is used. To allow changing of materials in a system, documented processes and
procedures for cleaning and verification of cleanliness that account for individual system
designs must be created. Should materials be switched, the system has to be verified clean before
qualification or requalification activities begin.

Feedstock Blending at the AM Part Producer

[EFCR-9] Powder or liquid blending operations occurring at the AM part producer shall be
controlled by procedures in the EFCP to prevent contamination and cross-contamination of
feedstock materials or feedstock lots, and to provide for safety in operations.

[Rationale: Blending operations (e.g., tumbling) are intended to ensure uniformity in powder
particle distribution by reducing segregation as a result of handling and other operations that
tend to segregate feedstocks. The blending process at the AM part producer has to follow
established procedures; otherwise, required control of the feedstock material may be lost.]

Blending of feedstock materials at the AM part producer assumes that the feedstock materials to
be blended still meet the applicable feedstock specifications and reuse limits. Blending of
feedstock materials helps ensure uniformity of the material and does not constitute a
recertification of the material.

Contamination and Foreign Object Debris Control

[EFCR-10] Plans and policies for the prevention of contamination and foreign object debris, as
defined and controlled by the QMS and referenced in the EFCP, shall be actively enforced
during all operations of AM machines and associated equipment.

[Rationale: Contamination and foreign object debris can easily undermine the integrity of the
AM process and frequently are the result of unintended and unnoticed actions. The requirement
to formalize and enforce plans and policies to preclude such contamination are essential to the
long-term integrity of the AM process.]

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Contamination control policies are intended to address the specifics of all operations, from
storage and handling of feedstock throughout the AM process to the removal of excess feedstock
from the machine during powder lot changeovers, in order to mitigate the risk of process
contamination, particularly during off-nominal operations (e.g., atypical maintenance or repair)
that may bring unusual opportunities for contamination. These policies should be addressed
specifically in the training for all personnel with unsupervised access to the AM machine
environment.

4.4 Digital Thread

Computer Security

[EFCR-11] Continuous computer security (i.e., cybersecurity or information technology

security) shall be established and maintained on all computer systems and related devices that
are associated with any aspect of the AM part design and build process, including storage
devices used to transfer files.

[Rationale: The AM process is fully dependent on digital programs and digitally stored and
manipulated data. The integrity of the AM process cannot be assured if the computer systems
associated with all aspects of the process are not properly secured.]

The CEO and AM part producer share responsibilities in maintaining computer security
commensurate with data integrity requirements. In the event that a computer cannot be secured
using software or similar means, the computer or control unit should be placed in a physically
controlled environment (e.g., standalone) or controlled access room.

Records Retention

[EFCR-12] Digital records considered to be part of the production engineering record according
to NASA-STD-6030 shall be retained in accordance with the contract or QMS requirements.

[Rationale: Records for all components of the digital thread have to be archived for the
prescribed period and remain fully traceable, including those provided by external suppliers.]

Sensitive Data

[EFCR-13] All AM-related data, including build parameters and part designs that are
designated as sensitive, as defined by the contract, shall be handled with commensurate
protections during all stages of transfer and storage.

[Rationale: Implementing the AM process involves the transfer, manipulation, and storage of
data, electronic or otherwise, that are potentially deemed sensitive and protected by law from
unauthorized disclosure. This requirement ensures all entities are aware that such precautions
may be necessary.]

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Both the CEO and the AM part producer are responsible for implementing the requirement
across all facilities and data-transfer operations. This requirement applies to any data,
including, but not limited to, drawings, models, and build files, which the CEO deems sensitive.

Policies and designations for data marking continuously evolve and vary by organization.
Examples of designations for sensitive data include Sensitive But Unclassified, Proprietary,
Limited Rights, International Traffic in Arms Regulations, Export Administration Regulations, or
Controlled Item per the United States Munitions List.

4.5 Installation Controls

[EFCR-14] Prior to beginning production on any AM equipment, the AM part producer shall
verify the following:

Installation conditions (e.g., temperature, humidity, floor profile and level) meet
original equipment manufacturer (OEM) guidelines.

Utilities (e.g., required process gasses, power, chilled/cooling water, etc.) are
available at required quantity or rating.

Ventilation needs and byproducts produced by AM equipment meet all applicable

environmental and safety standards.

All factory acceptance testing and site acceptance testing required by the machine
manufacturer has been successfully completed.

Hazard mitigation systems (e.g., fire protection and electrostatic grounding) are
consistent with OEM recommendations and all applicable environmental, health, and safety
standards.

[Rationale: Installation qualification ensures AM equipment and process installations meet

OEM and regulatory guidelines for installation, environment, health, and safety.]

Installation controls are intended to verify AM process equipment has been installed and
commissioned per the OEM guidelines and recommendations. This includes facility preparation
to OEM specifications, safety and hazard requirements meeting all safety rules and regulations,
and verification equipment performance to OEM guidelines. This body of work is critical to the
establishment of safe and sustainable AM production.

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4.6 Operational Controls

This section specifies required controls for equipment calibration, maintenance, monitoring, and
procedure controls.

Operational Procedures and Checklists

[EFCR-15] Detailed operational procedures and checklists for all AM machines and associated
equipment shall be used, and referenced in the EFCP, to ensure facility operations are
standardized to the fullest extent possible, to provide operators with a proactive method to ensure
all procedural steps are completed, and to provide traceability to the relevant QMS documents
and forms (i.e., command media).

[Rationale: Consistency in the execution of sensitive processes, such as AM, is critical to

maintaining control. Formalized procedures and checklists for complex operations are the key to
achieving operational consistency.]

Development of these procedural work instructions or checklists is the responsibility of the AM

part producer and may be implemented in any manner suiting the operational norms of the
facility. Procedures or checklists are intended to be sufficiently detailed such that they are fully
specific to a given machine or piece of equipment and are intended to be in place for all
standard and readily foreseen contingency situations arising in normal operations (e.g., powder
handling/filling, build setup and execution, build completion and removal of parts, powder
removal from parts, machine cleaning, and other such common operations). Checklists also
provide an easy way to confirm that all required steps were taken.

In Situ Monitoring

[EFCR-16] In situ monitoring systems shall be maintained and calibrated per a NASA-
approved specification.

[Rationale: In situ monitoring systems are becoming increasingly common in AM and, if used,
have to be maintained and calibrated on a regular basis.]

Maintenance and calibration guidelines supplied by the OEM may or may not be sufficient to
meet the requirements of section 4.9 of NASA-STD-6030. The NASA-approved specification
should contain the maintenance and calibration procedures and the schedules for these
operations.

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Configuration Management of AM Machines

[EFCR-17] A configuration management log for each AM machine shall be controlled by the
QMS and include, at a minimum, the following events:

Maintenance, calibration, and qualification events.

Machine manufacturer service calls.

Repairs or other changes to machine.

Changes to associated computers used in production of files for printing (e.g.,

changes in computer-aided design and slicing software).

Updates to software and firmware versions.

[Rationale: Maintaining an accurate record of machine configuration is necessary to (1)

establish the state of the AM machine at the time of qualification, (2) track or identify machine
changes that may influence qualification status and the quality of the AM process, and (3)
prevent unplanned or unintended loss of configuration control. Loss of AM machine
configuration control negates the process control logic at the foundation of these requirements.]

In addition to the AM machine, changes in the way the computer model is rendered and sliced
can affect the build with unintended consequences.

Maintenance

[EFCR-18] Comprehensive preventive maintenance schedules shall be established and

enforced for all AM machines, facilities, and associated equipment.

[Rationale: Sustaining a continuously controlled AM process is only feasible if maintenance for

the facility and all associated equipment is performed consistently and adequately.]

Facility and equipment maintenance is intended to be implemented through the EFCP under the
auspices of the AM part producer. The preventive maintenance schedules should include, at a
minimum, the recommended maintenance items identified by the AM machine manufacturer and
other items unique to the installation or facility. The maintenance schedule should be reviewed
periodically for each AM machine to ensure all maintenance needs and intervals are properly
set, proactively taking into account observations of process quality and machine health during
operations and prior maintenance activity. Critical associated equipment may include sieve
equipment, measuring or calibration instruments, cleaning tools, and other such apparatus that
are influential to continued successful operation of the AM process.

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Minimum Maintenance

[EFCR-19] Preventative maintenance plans for AM equipment shall meet, at a minimum, those
required by the machine OEM.

[Rationale: OEM required maintenance is considered the minimum effort required for AM
equipment.]

Associated Equipment

[EFCR-20] Any associated equipment whose performance can impact the ability of the AM
parts produced to meet the specified requirements (e.g., solvent tank or powder removal systems)
shall be included in the maintenance plan.

[Rationale: All maintenance performed has to be documented in a log and maintained for a
period compliant with applicable contracts and laws.]

Calibration

Calibration of AM machines and associated equipment is central to establishing the qualification

of machines for production. This section provides minimum requirements for managing
calibrations. The metrology and calibration requirements below are those that are unique and
impactful for managing AM processes. See NPR 8735.2, Management of Government Quality
Assurance Functions for NASA Contracts, and NASA-STD-8739.12, Metrology and Calibration,
for requirements applicable to NASA programs and projects for using and flowing down
metrology and calibration requirements to external suppliers.

4.6.7.1 Calibration Schedules

[EFCR-21] Each AM machine shall have comprehensive calibration schedules defined and
implemented that meet the following minimum criteria:

Addresses all mechanical, optical, electrical, software, and firmware systems

involved in controlling or monitoring the AM process.

Defines each calibration metric with nominal value(s) and acceptable tolerances.

Defines calibration intervals for each metric.

Is subject to the metrology and calibration program requirements imposed by the

contract.

[Rationale: Equipment calibration is essential to reliable control of the AM process.]

Equipment calibration procedures are intended to be implemented through the EFCP under the
auspices of the AM part producer. Calibration may also include or be limited to verification of

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state, such as in the case of software or firmware versions. All aspects of the AM machine that
are controlled, commanded, or monitored during execution of the AM process are intended to be
included in the calibration and verification process. These include, but are not limited to, the
ventilation system, oxygen sensing, and motion and alignment of mechanical systems (e.g., the
recoater and build platform). Use of National Institute of Standards and Technology (NIST)-
traceable standards for all calibration measurements is recommended. NASA-STD-6033 does
not modify NASA metrology and calibration policy, which is found in NPR 8735.2 and NASA-
STD-8739.12. Refer to the contract for calibration control requirements.

4.6.7.2 Optical System Calibration

[EFCR-22] As part of the calibration schedule, calibration of the optical system(s) (e.g., lasers,
scanner heads, and associated optical path) of each laser/light-based AM machine shall include,
at a minimum for each laser/scanner combination, the following metrics evaluated at the center
and furthest attainable extremes of the build area (or individual laser scan area) in the build
plane:

Laser/light power.

Laser/light spot size, shape, and profile.

Laser/light alignment (X, Y) to the build area and with relationship to additional
lasers in the system.

Laser/light focal point alignment to the build plane.

Accuracy and precision of scanner head beam scanning.

Laser timing for on/off operations during a build.

[Rationale: The AM process is wholly dependent on optical system performance. AM machines

are typically incapable of active feedback monitoring of optical system performance. These
calibration requirements are established to provide consistent monitoring of optical system
health.]

Depending on the capabilities of the AM part producer, optical system calibration is likely a set
of measurements to verify that the health of the laser and optics system is consistent with metrics
provided by the equipment manufacturer and consistent over time. Lasing purposeful markings
into a flat, solid plate and evaluating the markings against metrics (based on past performance)
may provide sufficient evidence of scanner head health.

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4.6.7.3 Calibration Intervals

[EFCR-23] Maximum calibration intervals shall be as follows:

Optical system(s): 90 days.

All other systems: 180 days.

After any maintenance, repair, or replacement of any system (e.g., repairing the scan
mirror system).

[Rationale: Calibration is effective only when maintained continuously. For pragmatic reasons,
confirming calibration is not feasible on a per-build basis. This time-based calibration interval is
set as a compromise between production efficiency and process assurance. In addition,
calibrations have to be reestablished after working on the system to perform maintenance and
repairs, as it is likely the system will be out of calibration initially.]

To accommodate part build times and schedules, these calibration intervals may be acceptably
implemented at the completion of the last build that began within the interval. Policies for
interpreting the calibration interval have to be clearly defined in the EFCP.

4.6.7.4 Calibration State

[EFCR-24] AM machines shall be considered in a calibrated state only when:

All scheduled maintenance items in section 4.6.4 of this NASA Technical Standard
are completed within their prescribed maintenance intervals,

All calibration metrics in section 4.6.7.2 of this NASA Technical Standard are
evaluated within their defined calibration intervals (maximums per section 4.6.7.3) and verified
within specification limits, and

Maintenance and calibration records are documented as required by section 4.6 of this
NASA Technical Standard.

[Rationale: An established and documented state of calibration is necessary to establish AM

machine qualification for the production of parts.]

4.6.7.5 Calibration Nonconformance

[EFCR-25] Upon calibration, if any calibration metric is not within specification limits, a
nonconformance shall be documented and controlled by the QMS for all parts produced since
the last calibration.

[Rationale: Calibration metrics outside specification limits are considered a nonconformance to

section 4.6.7.2 of this NASA Technical Standard.]

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This requirement may influence the choice of calibration intervals to mitigate programmatic
risk, particularly for AM machines whose calibration stability is not well characterized. Part
nonconformance can be resolved at the discretion of the program, preferably once the root cause
of the calibration error and its influence on the AM process is understood.

4.7 AM Machine Qualification

[EFCR-26] AM machines shall have active qualification status only when:

The AM machine is documented to be in the calibrated state per section 4.6.7.2 of this
NASA Technical Standard,

A QMP or sub-QMP has been successfully established within 12 months, or the AM

machine has been under continuous SPC monitoring as defined by NASA-STD-6030, and

No event (see the following examples) has occurred to negate the active qualification
status of the machine:

(1) Changes to the machine other than predefined preventative maintenance.

(2) Updates to software or firmware.
(3) Replacement, repair, or alteration of predetermined list of critical components.
(4) Moving the machine.
(5) Changes to the machine setup or configuration within the facility.
(6) Any similar or unforeseen event that may credibly alter or influence the AM
machine performance.
(7) There is no pending, unresolved nonconformance associated with compliance
with the controls defined in section 4.6 of this NASA Technical Standard.

[Rationale: A clearly implemented definition of AM machine qualification status ensuring

machine health is critical to the reliable production of AM parts.]

Predetermining an exhaustive list of events that negate the active qualification status of a
machine is not practical, and determining which disruptive events reach this threshold can be
subjective. The list of critical components of an AM system will vary depending on multiple
factors (e.g., machine architecture and material). A list of these components have to be
documented prior to a machine’s initial qualification. Accurate documentation of all events,
regardless of magnitude, in the machine configuration management log (see section 4.6.3 of this
NASA Technical Standard) is important. Unforeseen events of questionable impact to
qualification state should be arbitrated among the AM part producer and/or the CEO.

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AM Machine Qualification Status for Production

[EFCR-27] AM parts shall be produced only to a QMP if the associated machine has active
qualification status and such qualification status is posted directly on the machine.

[Rationale: The qualification of an AM machine and the qualification of its associated

metallurgical processes are largely synonymous, given the machine is in a calibrated state.
Verification of the quality of the metallurgical process establishes the AM machine’s
qualification; events that negate a machine’s qualification status negate the ability to produce
parts to associated QMPs until machine qualification status is reestablished. Posting of machine
qualification status ensures operators are noticeably aware of a machine’s status prior to use.]

Establishing Initial Qualification

[EFCR-28] Active qualification status of an AM machine shall be established initially through

the following:

Verify the AM machine meets all OEM requirements and specifications and has been
certified as operational by the OEM upon installation.

Verify the AM machine to be in a calibrated state per section 4.6.7.2 of this NASA
Technical Standard.

Verify one QMP (or sub-QMP, as applicable) for the machine meets the requirements
of section 5 of NASA-STD-6030 or the applicable AMCP approved by the CEO.

Record the active qualification status in the AM machine configuration log.

[Rationale: These requirements represent the minimally acceptable evaluations of AM machine

performance prior to production of parts.]

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Reestablishing Qualification

[EFCR-29] Active qualification status of an AM machine shall be reestablished following any

event that negates its active qualification status through a minimum of the following:

Verify the event negating active qualification is resolved.

Verify the AM machine is in a calibrated state per section 4.6.7.2 of this NASA
Technical Standard.

Verify the AM process using the SPC requirements of NASA-STD-6030, section 5.5,
or the applicable AMCP approved by the CEO.

Record all related events in the AM machine configuration log.

[Rationale: These requirements represent the minimally acceptable evaluations of AM machine

performance to requalify the machine for production of parts following an event that negates an
active qualification status.]

An AM machine may have multiple associated QMPs (e.g., QMPs developed for various layer
thicknesses). An AM machine without active qualification status may not produce to any of its
associated QMPs. Reestablishing active qualification status and enabling all associated QMPs
require reevaluation of the machine capability per NASA-STD-6030, section 5.5, or the
applicable AMCP approved by the CEO for only one of the associated QMPs.

As discussed in the commentary for section 4.7 of this NASA Technical Standard, a broad variety
of events may occur to negate the qualification status of an AM machine. The scope of
requalification activities may be tailored to fit unique scenarios with written agreement of the
AM part producer, the CEO, and the NASA customer.

4.8 Operator Certification

[EFCR-30] AM operations, defined in the context of this requirement as those actions spanning
from the manipulation of the digital product definition to prepare for the build through removal
of the completed part from the AM machine, shall only be performed by operators with
applicable training certifications traceable via a records management system controlled by the
QMS and to minimum training requirements defined by the machine’s OEM.

[Rationale: Although automated, the AM process is highly sensitive and dependent on the inputs
of the operators at all stages of the process. Operator certifications are essential to minimizing
the risk of human error in the process. Operators should meet, at a minimum, the training
requirements specified by the equipment OEMs.]

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Training Program

[EFCR-31] An active operator training program shall be defined, maintained, and implemented
to meet the following objectives:

Provide a consistent framework for training and certification requirements.

Provide clear delineations of abilities and responsibilities associated with granted

certifications.

Provide operators with all necessary skills, knowledge, and experience to safely and
reliably execute the responsibilities of their certification.

Provide for operator evaluations that demonstrate adequacy in skills, knowledge, and
experience to grant certifications to personnel, ensuring only properly trained and experienced
personnel have appropriate certifications.

Incorporate content regarding the importance, purpose, and use of the QMS for all
aspects of the established AM process.

[Rationale: Operator certifications are only meaningful if granted from a properly structured
and adequate training program.]

The CEO and AM part producers are jointly responsible for the adequacy of the implemented
training program.

The intent of this requirement is to ensure appropriate depth in the knowledge and skills of the
AM workforce involved in the production of aerospace parts per these NASA Technical
Standards.

A list of key topics for training and an example of a training program can be found in extended
commentary of Appendix B.

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APPENDIX A

REQUIREMENTS COMPLIANCE MATRIX

A.1 PURPOSE
Due to the complexity and uniqueness of space flight, it is unlikely that all of the requirements in a NASA technical standard will
apply. The Requirements Compliance Matrix below contains this NASA Technical Standard’s Technical Authority requirements and
may be used by programs and projects to indicate requirements that are applicable or not applicable to help minimize costs. Enter
“Yes” in the “Applicable” column if the requirement is applicable to the program or project or “No” if the requirement is not
applicable to the program or project. The “Comments” column may be used to provide specific instructions on how to apply the
requirement or to specify proposed tailoring.

NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.1 Tailoring of this NASA [EFCR-1] Tailoring of this NASA Technical Standard’s requirements in
Technical Standard’s the EFCP shall be formally documented as part of program or project
Requirements requirements and approved by the responsible program/project NASA
Materials and Processes (M&P) organization, the responsible
project/program, and the delegated Technical Authority in accordance
with NPR 7120.5, NASA Space Flight Program and Project Management
Requirements, or NPR 7120.8, NASA Research and Technology Program
and Project Management Requirements.
4.2 Equipment and Facility [EFCR-2] Prior to approval of an AMCP created under the auspices of
Control Plan NASA-STD-6030, a CEO-approved EFCP shall be developed and
controlled by the QMS, addressing, at a minimum, the means of
conformance, the method of implementation, and the tailoring rationale for
each EFCR requirement in this NASA Technical Standard.
4.3.1 Feedstock Traceability [EFCR-3] Traceability of the feedstock materials and the certificate of
compliance shall be maintained throughout the lifecycle of the part.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.3.2 Feedstock Storage and [EFCR-4] The EFCP shall specify policies and procedures controlling
Handling the storage and handling of feedstock material, including, at a minimum,
the following aspects:
Identification of the individual responsible for controlling access to
feedstock and tracking usage.
Health and safety hazards.
Fire hazards associated with feedstock.
Safety Data Sheets.
Material and lot number identification for every container.
Storage in area with controlled access and suitable environmental
controls and conditions (e.g., temperature and humidity control).
Control of opened, partially used feedstock containers.
Tracking of feedstock expiration date when applicable.
Control of contamination and feedstock cross-contamination.
Procedural implementation of feedstock reuse controls per section
6.6 of NASA-STD-6030 required by the CEO-approved AMCP.
Disposal procedures.
4.3.3 Material Exclusivity in [EFCR-5] Each AM machine using powder feedstock shall be dedicated
AM Systems using to a single material.
Powder Feedstock
4.3.3.1 Powder or Liquid [EFCR-6] The number of feedstock lots present in a powder- or liquid-
Feedstock Lot Control based AM machine at any given time shall be controlled based on
Requirements in AM maximum machine build volume:
Machines Only one feedstock lot is allowed in AM machines with a build
volume capacity less than or equal to 0.05 m3 (1.75 ft3).
A maximum of two feedstock lots is allowed in AM machines with
a build volume capacity greater than 0.05 m3 (1.75 ft3).

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.3.3.2 Wire Feedstock Lot [EFCR-7] AM machines using wire feedstock shall be limited to a single
Control Requirements in feedstock lot present in the machine at any time.
AM Machines
4.3.3.3 Cleaning Procedures for [EFCR-8] Each AM machine building Class A or B hardware per NASA-
Removal of Residual STD-6030 shall have documented procedures for cleaning out residual
Feedstock feedstock and evaluating cleanliness, which are used prior to introducing
new material lots per the material exclusivity requirements of section 4.3.3
of this NASA Technical Standard, or when thorough cleanouts associated
with removing nonconforming lots or material changover are required.
4.3.4 Feedstock Blending at the [EFCR-9] Powder or liquid blending operations occurring at the AM part
AM Part Producer producer shall be controlled by procedures in the EFCP to prevent
contamination and cross-contamination of feedstock materials or feedstock
lots, and to provide for safety in operations.
4.3.5 Contamination and [EFCR-10] Plans and policies for the prevention of contamination and
Foreign Object Debris foreign object debris, as defined and controlled by the QMS and
Control referenced in the EFCP, shall be actively enforced during all operations of
AM machines and associated equipment.
4.4.1 Computer Security [EFCR-11] Continuous computer security (i.e., cybersecurity or
information technology security) shall be established and maintained on
all computer systems and related devices that are associated with any
aspect of the AM part design and build process, including storage devices
used to transfer files.
4.4.2 Records Retention [EFCR-12] Digital records considered to be part of the production
engineering record according to NASA-STD-6030 shall be retained in
accordance with the contract or QMS requirements.
4.4.3 Sensitive Data [EFCR-13] All AM-related data, including build parameters and part
designs that are designated as sensitive, as defined by the contract, shall be
handled with commensurate protections during all stages of transfer and
storage.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.5 Installation Controls [EFCR-14] Prior to beginning production on any AM equipment, the AM
part producer shall verify the following:
Installation conditions (e.g., temperature, humidity, floor profile and
level) meet original equipment manufacturer (OEM) guidelines.
Utilities (e.g., required process gasses, power, chilled/cooling water,
etc.) are available at required quantity or rating.
Ventilation needs and byproducts produced by AM equipment meet
all applicable environmental and safety standards.
All factory acceptance testing and site acceptance testing required
by the machine manufacturer has been successfully completed.
Hazard mitigation systems (e.g., fire protection and electrostatic
grounding) are consistent with OEM recommendations and all
applicable environmental, health, and safety standards.
4.6.1 Operational Procedures [EFCR-15] Detailed operational procedures and checklists for all AM
and Checklists machines and associated equipment shall be used, and referenced in the
EFCP, to ensure facility operations are standardized to the fullest extent
possible, to provide operators with a proactive method to ensure all
procedural steps are completed, and to provide traceability to the relevant
QMS documents and forms (i.e., command media).
4.6.2 In Situ Monitoring [EFCR-16] In situ monitoring systems shall be maintained and calibrated
per a NASA-approved specification.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.6.3 Configuration [EFCR-17] A configuration management log for each AM machine shall
Management of AM be controlled by the QMS and include, at a minimum, the following
Machines events:
Maintenance, calibration, and qualification events.
Machine manufacturer service calls.
Repairs or other changes to machine.
Changes to associated computers used in production of files for
printing (e.g., changes in computer-aided design and slicing
software).
Updates to software and firmware versions.
4.6.4 Maintenance [EFCR-18] Comprehensive preventive maintenance schedules shall be
established and enforced for all AM machines, facilities, and associated
equipment.
4.6.5 Minimum Maintenance [EFCR-19] Preventative maintenance plans for AM equipment shall
meet, at a minimum, those required by the machine OEM.
4.6.6 Associated Equipment [EFCR-20] Any associated equipment whose performance can impact the
ability of the AM parts produced to meet the specified requirements (e.g.,
solvent tank or powder removal systems) shall be included in the
maintenance plan.
4.6.7.1 Calibration Schedules [EFCR-21] Each AM machine shall have comprehensive calibration
schedules defined and implemented that meet the following minimum
criteria:
Addresses all mechanical, optical, electrical, software, and firmware
systems involved in controlling or monitoring the AM process.
Defines each calibration metric with nominal value(s) and
acceptable tolerances.
Defines calibration intervals for each metric.
Is subject to the metrology and calibration program requirements
imposed by the contract.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.6.7.2 Optical System [EFCR-22] As part of the calibration schedule, calibration of the optical
Calibration system(s) (e.g., lasers, scanner heads, and associated optical path) of each
laser/light-based AM machine shall include, at a minimum for each
laser/scanner combination, the following metrics evaluated at the center
and furthest attainable extremes of the build area (or individual laser scan
area) in the build plane:
Laser/light power.
Laser/light spot size, shape, and profile.
Laser/light alignment (X, Y) to the build area and with relationship
to additional lasers in the system.
Laser/light focal point alignment to the build plane.
Accuracy and precision of scanner head beam scanning.
Laser timing for on/off operations during a build.
4.6.7.3 Calibration Intervals [EFCR-23] Maximum calibration intervals shall be as follows:
Optical system(s): 90 days.
All other systems: 180 days.
After any maintenance, repair, or replacement of any system (e.g.,
repairing the scan mirror system).

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.6.7.4 Calibration State [EFCR-24] AM machines shall be considered in a calibrated state only
when:
All scheduled maintenance items of section 4.6.4 of this NASA
Technical Standard are completed within their prescribed
maintenance intervals,
All calibration metrics in section 4.6.7.2 of this NASA Technical
Standard are evaluated within their defined calibration intervals
(maximums per section 4.6.7.3) and verified within specification
limits, and
Maintenance and calibration records are documented as required by
section 4.6 of this NASA Technical Standard.
4.6.7.5 Calibration [EFCR-25] Upon calibration, if any calibration metric is not within
Nonconformance specification limits, a nonconformance shall be documented and
controlled by the QMS for all parts produced since the last calibration.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.7 AM Machine [EFCR-26] AM machines shall have active qualification status only
Qualification when:
The AM machine is documented to be in the calibrated state per
section 4.6.7.2 of this NASA Technical Standard,
A QMP or sub-QMP has been successfully established within 12
months, or the AM machine has been under continuous SPC
monitoring as defined by NASA-STD-6030, and
No event (see the following examples) has occurred to negate the
active qualification status of the machine:
1. Changes to the machine other than predefined preventative
maintenance.
2. Updates to software or firmware.
3. Replacement, repair, or alteration of predetermined list of
critical components.
4. Moving the machine.
5. Changes to the machine setup or configuration within the
facility.
6. Any similar or unforeseen event that may credibly alter or
influence the AM machine performance.
7. There is no pending, unresolved nonconformance associated
with compliance with the controls defined in section 4.6 of this
NASA Technical Standard.
4.7.1 AM Machine [EFCR-27] AM parts shall be produced only to a QMP if the associated
Qualification Status for machine has active qualification status and such qualification status is
Production posted directly on the machine.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.7.2 Establishing Initial [EFCR-28] Active qualification status of an AM machine shall be
Qualification established initially through the following:
Verify the AM machine meets all OEM requirements and
specifications and has been certified as operational by the OEM
upon installation.
Verify the AM machine to be in a calibrated state per section 4.6.7.2
of this NASA Technical Standard.
Verify one QMP (or sub-QMP, as applicable) for the machine meets
the requirements of section 5 of NASA-STD-6030 or the applicable
AMCP approved by the CEO.
Record the active qualification status in the AM machine
configuration log.
4.7.3 Reestablishing [EFCR-29] Active qualification status of an AM machine shall be
Qualification reestablished following any event that negates its active qualification
status through a minimum of the following:
Verify the event negating active qualification is resolved.
Verify the AM machine is in a calibrated state per section 4.6.7.2 of
this NASA Technical Standard.
Verify the AM process using the SPC requirements of NASA-STD-
6030, section 5.5, or the applicable AMCP approved by the CEO.
Record all related events in the AM machine configuration log.
4.8 Operator Certification [EFCR-30] AM operations, defined in the context of this requirement as
those actions spanning from the manipulation of the digital product
definition to prepare for the build through removal of the completed part
from the AM machine, shall only be performed by operators with
applicable training certifications traceable via a records management
system controlled by the QMS and to minimum training requirements
defined by the machine’s OEM.

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NASA-STD-6033
Applicable
Section Description Requirement in this Standard (Enter Yes Comments
or No)
4.8.1 Training Program [EFCR-31] An active operator training program shall be defined,
maintained, and implemented to meet the following objectives:
Provide a consistent framework for training and certification
requirements.
Provide clear delineations of abilities and responsibilities associated
with granted certifications.
Provide operators with all necessary skills, knowledge, and
experience to safely and reliably execute the responsibilities of their
certification.
Provide for operator evaluations that demonstrate adequacy in skills,
knowledge, and experience to grant certifications to personnel,
ensuring only properly trained and experienced personnel have
appropriate certifications.
Incorporate content regarding the importance, purpose, and use of
the QMS for all aspects of the established AM process.

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APPENDIX B

OPERATOR TRAINING

B.1 PURPOSE
This Appendix provides examples of key topics expected to be included in a training program
and an example training protocol.

B.2 KEY TOPICS TO INCLUDE IN A TRAINING PROGRAM

Following are examples of key topics expected to be included in a training program (does not
represent a comprehensive list):

 Health and safety.

 Understanding and using the QMS.
 Documentation requirements.
 Maintaining configuration control of digital files and equipment.
 Working with the digital product definition.
 The cryptographic hash and its use.
 Build files, support structures, slicing.
 Feedstock handling.
 Machine functionality: setup, operations, restarts, maintenance, calibration.
 AM process monitoring: understanding failure mechanisms in the process and the ability
to identify and properly troubleshoot build errors.
 Understanding build capability: overhangs, surface quality, detail resolution.
 As-built part inspections for build quality and anomalies.
 Contamination and foreign object debris control.
 Execution and evaluation of standard qualification build sets for QMP and SPC purposes.
 Establishing QMPs and sub-QMPs.

B.3 EXAMPLE TRAINING PROTOCOL FOR LASER POWDER BED

FUSION (L-PBF) MACHINE OPERATORS

The following example represents a training protocol for L-PBF machine operators with tiered
implementation meeting the objectives of section 4.8.1 of this NASA Technical Standard:

Note: A similar training regiment, though perhaps not tiered, would be needed to cover topics
related to working with the digital product definition (e.g., assembling builds, slicing, support
generation, and related tasks).

Trainee

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Prerequisites:
 No prior experience needed.

Typical duties:
 Trainee may participate in the day-to-day operations of L-PBF machines and associated
equipment. A trainee is not to operate L-PBF machines or associated equipment without
the supervision of at least a Level I Certified Operator.

Level I Certified Operator

Prerequisites:
 Minimum 3 months of experience under direct supervision of a Level II or III
Certified Operator.
 Passed written and practical test administered by a Level III Certified Operator.
 Completed all basic training offered by the L-PBF machine manufacturer.
 Full understanding of applicable QMS and associated responsibilities.

Typical duties:
 Machine cleaning, operational checks.
 Basic machine operations.
 Execution of established builds.
 Operate under supervision of Level II or III Certified Operator.

Level II Certified Operator

Prerequisites:
 Met all Level I Certified Operator prerequisites.
 One-year minimum experience under direct supervision of a Level II or III Certified
Operator.
 Passed written and practical test administered by a Level III Certified Operator.
 Completed all advanced training offered by the L-PBF machine manufacturer.
 Comprehensive knowledge of all machine functions.

Typical duties:
 Set up and troubleshoot L-PBF equipment.
 Execute and analyze standard qualification build sets.
 Troubleshoot and iteration of build schemes to optimize build performance.
 Build file generation in accordance with qualified part process requirements.
 Develop machine operation checklists.
 Operate under supervision of Level III Certified Operator.

Level III Certified Operator

Prerequisites:

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 Met all Level II Certified Operator prerequisites.

 Minimum 3 years of experience.
 Understanding of the physics and metallurgy of the L-PBF process.
 Passed written and practical test administered by another Level III Certified Operator.

Typical duties:
 Develop QMPs.
 Establish proper QMS oversight for all L-PBF activities.
 Develop, implement, and approve production planning records.
 Set machine calibration metrics and intervals.
 Develop training and administer written and practical certification tests.

The structure provided above is a reference only and does not dictate how a training program is
to be set up. There are many universities, standards developing organizations, and other entities
that are developing training programs that may provide training resources to meet the needs of
the organization and the requirements of this NASA Technical Standard. For example, in the
tiered example provided above, courses such as Society of Manufacturing Engineers “Additive
Manufacturing Technician Certification” or the ASTM “Additive Manufacturing Center of
Excellence Training” may provide content needed for the Level III certified operator.

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APPENDIX C

REFERENCES

C.1 PURPOSE

This Appendix provides references to guidance documents related to this NASA Technical
Standard.

C.2 REFERENCES

MSFC Form 4657, Change Request for a NASA Engineering Standard

NASA-STD-8739.12, Metrology and Calibration

NPR 8735.2, Management of Government Quality Assurance Functions for NASA Contracts

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