The Applied Science and Technology Research Organization (ASTRO) America, a nonprofit research institute specializing in manufacturing policy and technology in aerospace and defense sectors, has deployed Plastometrex’s PLX-Benchtop system into its additive friction stir deposition (AFSD) workflows. The integration aims to streamline and accelerate mechanical characterization during process development.
Plastometrex, a UK-based company founded by scientists from the University of Cambridge, specializes in mechanical testing systems that deliver accurate stress-strain data through non-destructive indentation methods. Since adopting the PLX-Benchtop, ASTRO America has conducted several hundred tests on aluminum alloys processed via MELD’s solid-state 3D printing technology.
At the heart of Plastometrex’s innovation is Profilometry-based Indentation Plastometry (PIP) technology, which provides a cost-effective, rapid alternative to traditional tensile testing. “The ability to conduct fast, non-destructive mechanical testing with PIP has significantly improved our approach to material optimization,” said Noah Barnhill, Vice President, Army Operations at ASTRO America. “We can now evaluate mechanical properties in real time, making data-driven decisions about process parameters without the delays and material constraints of conventional testing methods.”
The PLX-Benchtop system enables ASTRO to assess part homogeneity directly on finished components, avoiding the logistical and material challenges posed by destructive testing. By leveraging PIP-based testing, ASTRO America has been able to analyze the impact of various print parameters more comprehensively and cost-effectively.
Mechanical testing traditionally represents a significant bottleneck in additive manufacturing research and development. Plastometrex’s platform transforms this dynamic by facilitating direct, localized analysis of 3D printed parts. Commenting on the deployment, Dr. Mike Coto, Chief Commercial Officer at Plastometrex, said, “ASTRO’s use of the PLX-Benchtop demonstrates how rapid, cost-effective mechanical testing can unlock deeper insights into process optimization, material performance, and component reliability – without the cost and time barriers of traditional tensile testing.”
The PIP testing process involves three key steps: creating a controlled indent in the material, conducting a 3D measurement of the indent's profile, and performing an inverse finite element analysis to extract mechanical properties. The entire cycle delivers critical material performance data—such as yield strength, ultimate tensile strength, and uniform elongation—in less than five minutes.
The system employs a spherical indenter of 0.5 to 1 millimeter radius to create an indent approximately 100–200 microns deep, ensuring the results reflect the material’s bulk behavior. A profilometer or interferometer then measures the indent’s 3D profile, with computational models refining the final stress-strain curves through iterative analysis.
Supporting Broader Standardization and Industry Investment Initiatives
ASTRO America’s adoption of Plastometrex’s PLX-Benchtop aligns with its broader efforts to advance additive manufacturing standardization and industry investment. Earlier this month, ASTM International commenced a three-year collaboration with ASTRO focused on developing qualification frameworks for AFSD technologies. The project, titled “Advancement of Process, Materials, Applications, and Test and Evaluation for Large-Scale Additive Manufacturing,” encompasses five technical phases and emphasizes improvements across equipment control, facility setup, feedstock parameters, and operational processes.
Simultaneously, ASTRO America has played a pivotal role in securing capital resources to promote additive manufacturing among small and medium-sized enterprises. The organization's AM Forward initiative recently gained federal approval for its private equity fund—the Stifel North Atlantic AM-Forward Fund—under the U.S. Small Business Administration’s Critical Technology initiative. Supported by major industrial stakeholders including Lockheed Martin, GE Aerospace, and ASTM International, the fund aims to address barriers such as capital access, machine qualification, and workforce development.
By integrating cutting-edge testing platforms like Plastometrex’s PLX-Benchtop and fostering supportive ecosystems for manufacturing innovation, ASTRO America continues to play a central role in advancing the capabilities and adoption of next-generation additive manufacturing technologies in the United States.
Reference: https://3dprintingindustry.com/news/astro-america-deploys-plastometrex-technology-to-accelerate-mechanical-testing-in-additive-friction-stir-deposition-238853/
