How do you qualify a metal additive manufacturing process for production parts?

Metal AM qualification involves: Machine qualification (IQ/OQ - installation and operational verification, beam characterization), Material qualification (powder certification, recycling procedures, chemistry control), Process parameter development (DOE for power, speed, hatch, layer thickness to optimize density >99.5%), Specimen testing (tensile, fatigue, creep at various orientations - account for anisotropy), NDE protocol development (CT scanning, surface inspection), Dimensional capability studies (accuracy, repeatability), Microstructure validation (grain structure, phase distribution), Heat treatment optimization, and Documentation for regulatory compliance (AS9100, NADCAP for aerospace). Build statistical database through coupon testing alongside production parts. Process monitoring (melt pool, thermal imaging) provides in-situ quality data.