The Tool Desk
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1. Define what “good” means for the part
Start with the part’s intended use and operating environment, not a generic list of material tests. Translate its job into critical-to-quality characteristics: the properties or behaviors that determine whether the part performs safely and reliably. For each one, establish a measurable acceptance limit and decide what evidence will demonstrate compliance. Include the consequences of failure; a cosmetic variation and a failure with safety consequences do not warrant the same decision threshold.
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Align the proposed limits and evidence with the supplier, engineering, quality, manufacturing and—where relevant—safety or regulatory stakeholders before testing. For a critical or regulated application, confirm the applicable qualification requirements with responsible experts. NIST describes itself as non-regulatory and notes that actual qualification protocols are determined by the responsible regulatory bodies; its additive-manufacturing guidance is not a universal release standard for other material families.
2. Record what is unfamiliar and preserve traceability
Document the material grade or formulation, supplier, lot, processing history, storage and handling conditions, and the differences from the known-good material or process. Tie each specimen and result to the specific material and trial that produced it. Without that connection, a favorable test result may not describe the material actually used in production.
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Also identify what decision the test must support. Incoming-material checks, processability trials and finished-part performance tests answer different questions; some evaluations need all three. A supplier certificate or a single successful specimen does not, by itself, establish that production will behave as expected.
3. Choose tests and specimens that represent the intended use
There is no universal test panel for an unfamiliar material. Select methods according to the material family and form, manufacturing route, intended performance and likely failure modes. Depending on the case, relevant evaluations may concern mechanical, thermal, chemical, dimensional, environmental or processability properties. Name a particular test method only after confirming that it applies to the material and decision at hand.
The specimen and method must represent both the material and the process. ASTM B925-15(2022) is a bounded example: it covers production and preparation of specimens for uniaxially compacted powder metallurgy (PM) and notes that specimen dimensions and tolerances must meet the applicable test method. Its scope should not be generalized to other powder routes or materials. Check the governing method’s specimen requirements before cutting or preparing samples; measuring dimensions alone does not show that a specimen is suitable for a property test.
For metal additive manufacturing
Metal AM illustrates why feedstock testing alone is not enough. NIST’s material-characterization work identifies properties such as rheological behavior, size and morphology, thermal properties, moisture-related behavior and metallurgical characteristics as relevant areas to consider. Conventional powder characterization does not necessarily predict how powder will spread or perform in a machine.
NIST’s metal-AM measurement program spans checks before a build, observations during a build and post-process inspection. Depending on the qualification question, evidence may include feedstock and machine checks, process signatures and powder-layer characteristics, then inspection or nondestructive evaluation of the finished build. Surface topography, internal defects and anisotropic or location-specific properties can complicate assessment. These are AM-specific examples, not a template to apply unchanged to plastics, coatings, castings or other material families.
4. Make sure the measurement system can support the decision
Plan instrument calibration and measurement system analysis (MSA) as part of the test plan. Verify that the method, instrument, specimen geometry and operator can resolve the property and tolerance that determine acceptance. If measurement variation is large relative to the acceptance window, apparent differences between samples may reflect the measurement system rather than the material.
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When outside testing is needed, compare laboratories on the relevant method and scope, sample representativeness, turnaround time, measurement capability and uncertainty, reporting detail, and applicable accreditation or qualification. The right provider is the one capable of producing evidence for the actual decision; no general provider ranking can substitute for checking fit to the material and method.
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Do not choose a sample count by habit or treat a few passing samples as proof of production suitability. The number and selection of samples depend on lot structure, variability, whether testing is destructive, the consequences of a false acceptance or rejection, governing standards and evidence already available. Set the sampling and acceptance rules before seeing the results, and involve a statistician or quality engineer when the decision is consequential.
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An ASQ-listed 2023 article on lot acceptance discusses setting reference values using an initial qualification sample. It also warns of the risk in treating the sample’s estimated mean and standard deviation as if they were known population parameters: doing so can create excessive producer risk. The article is not a universal acceptance procedure, and it does not support a single sample count or pass threshold for every material.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.6. Run a controlled trial and review the evidence
Where possible, hold process conditions constant and record deviations, so results can be attributed to the material change rather than an untracked process change. Compare test results and process behavior with the baseline and the acceptance criteria defined in advance. For a metal AM trial, organize observations across pre-process, in-process and post-process stages as applicable.
Then make an explicit, documented decision: reject the material, request additional testing, run a limited pilot, or release it under a defined control plan. A sample test is not automatically a production qualification. Qualification means assembling sufficient evidence that the material or process will perform as expected. For additive manufacturing, NIST describes three broad approaches:
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| Approach | What it relies on | When its logic may fit |
|---|---|---|
| Statistical-based | Extensive empirical testing to establish performance. | When the qualification case needs direct statistical evidence and the test burden is feasible. |
| Equivalence-based | Testing intended to show equivalence to a previously qualified material or process. | When a suitable qualified baseline exists and the relevant similarities can be demonstrated. |
| Model-based | Model evidence verified with testing. | When a model can support the case and verification testing is part of the evidence. |
These approaches are not interchangeable shortcuts. The appropriate route depends on application and regulatory requirements, how similar the new material or process is to a qualified baseline, available evidence and the consequences of being wrong. NIST’s figures for AM standardization gaps describe gaps in that field, not the number of tests required for an individual production decision.
Quick Recap
What to include in the test plan
- Intended use, operating conditions and likely failure modes.
- Critical-to-quality characteristics, measurable limits and required evidence.
- Material identity, supplier and lot, handling history, and comparison baseline.
- Sampling rationale, specimen preparation and applicable test methods.
- Calibration, MSA and inspection planning.
- Controlled-trial conditions, deviation records and decision rules.
- Disposition options and any control plan required for a pilot or release.
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