Theta Technologies: Advanced NDT solutions for additive manufacturing, metals, and composites.
Welcome to Theta Technologies, the forefront innovators in non-destructive testing (NDT) tailored for additive manufacturing, conventional metals, and composite components for critical applications. As manufacturing evolves, and more intricate designs and complex geometries become increasingly common, traditional NDT methods struggle to keep up. That’s where we come in.Â
Unleash the power of RD1-TT:
Test complex additive-manufactured parts
Theta Technologies’ nonlinear resonance non-destructive testing solution delivers where others have failed. Here is how RD1-TT can provide you with unrivaled design freedom for additive manufactured parts.
Validate one-off parts
RD1-TT’s ability to perform non-destructive tests without the need for ‘known good’ reference samples helps you fully understand the condition of individual components.
Topological optimisation
RD1-TT is capable of identifying smaller flaws than other NDT methods. Repeatability tests have consistently highlighted the machine’s capabilities to detect flaws as small as 10 microns.
Uncover flaws unique to AM
It’s no secret that AM has had its quality assurance challenges due to a unique set of flaws. RD1-TT all but eradicates these challenges with its unique approach to NDT.
Topological optimsation
Unlike other advanced NDT techniques, the resolution limits of the RD1-TT whole-body resonance are yet to be truly defined. 10-micron flaws in test pieces greater than 100 mm have been repeatedly detected by the RD1-TT NLR algorithms. Combining this with the ability to excite complex internal structures means that the part you always wanted to make but couldn’t inspect can now be inspected.
Resonance techniques are often impacted by materials with inherently high levels of damping, however, the RD1-TT has been put to the test by manufacturers producing metallic, polymeric, and ceramic parts in various post-printing conditions and geometries. It can even indicate how strong the bonds are between your polymer and fill matrix!
Metallic AM parts with complex internal geometry are a target for applications like heat exchangers, where a non-conventional casing made of temperature-dissipating materials would provide huge benefits to the end user. That request comes at a cost, however, as metals like Copper – perfect for this application, are dense enough to cause other NDT, such as X-CT, a number of issues. RD1-TT isn’t constrained by that – if we can get the part excited, we can get a nonlinear indication!
The Case Study | Additive Manufacturing
Nonlinear resonance NDT: identifying flaws in complex 3D printed metal parts.
In the rapidly advancing world of metal additive manufacturing, the quest for an effective non-destructive testing (NDT) solution remains. Heat exchangers, vital in automotive applications, epitomise the intricacy of 3D printed structures. Theta Technologies’ RD1-TT, with its nonlinear resonance NDT technology demonstrates its capability of handling complex metal AM designs and offering swift post-build evaluations.
welcome to Theta Technologies
Welcome to Theta Technologies, specialists in innovative non-destructive testing (NDT) technology for safety-critical applications across industries like aerospace, defense, automotive, and power generation. Our unique NDT solutions are designed to unlock the full potential of additive manufacturing. With our groundbreaking RD1-TT technology, we offer rapid and accurate flaw detection, even in the most intricate 3D-printed metal parts. Discover how we’re revolutionising the NDT landscape and setting new standards for quality assurance in additive manufacturing.
NDT for Metals
The go-to material for manufacturers for decades. Metals have been the building block of most industries thanks to its unrivalled strength and versatility.
NDT for Additive Manufacture
3D printing offers manufacturers greater design freedom, but the increasing geometries and complexities on offer means that existing NDT methods are no longer suitable.
NDT for Composites
Since the mid 1990s, composites have been widely used in manufacturing processes thanks to its relatively low cost, light weight, and incredible strength.
Featured:
Feature | NDT for additive manufacture
Theta Technologies and Plymouth Science Park: Pioneering flaw seeding for AM metals.
A pioneering flaw-creation process that not only accentuates the sensitivity of Theta Technologies’ non-destructive testing (NDT) method but also lays the foundation for validating other NDT techniques for additive manufacturing.
Case Study | NDT for additive manufacturing
Nonlinear resonance NDT: Unlocking the design potential of metal additive manufacturing
The complex geometries available with additive manufacturing are unquestionably one of the most appealing factors when looking to adopt this versatile technology, but existing non-destructive testing techniques have failed to help deliver confidence in AM part validation. Discover how Theta Technologies’ nonlinear resonance NDT technology has helped AM part manufacturers with this case study.
Case Study Details
The parts: Metal Valves
Manufacturing method: Additive Manufacturing
Previous inspection method: Dye Penetrant/Visual Inspection
Collaborators: Puntozero, m4p Material Solutions Gmbh
Key Take Away #1
Nonlinear resonance NDT was capable of successfully testing 3D printed metal valves for defects and flaws.
Key Take Away #2
Theta Technologies’ RD1-TT was able to successfully identify flaws within the additive-manufactured components.
Key Take Away #3
Reproducibility tests were performed to validate the results and assess the overall condition of the 3D printed parts.
Latest Videos
We’re big fans of video content. Take a look at some of our latest videos below.
EXPLORE OUR DIGITAL LIBRARY
Issue #1
THE CASE STUDY
Nonlinear resonance NDT: Unlocking the design potential of metal AM.Â
Issue #2
THE CASE STUDY
Nonlinear resonance NDT: The rapid assessment of creep in nickel superalloy turbine blades
Issue #1
THETA TECHNOLOGIES NEWS
BAE Systems and AMRC North West put RD1-TT to the test in major collaboration
HIGHLY COMMENDED PRODUCT
POST-PROCESSING AWARD
This game-changing non-destructive testing solution has been recognised at this year’s TCT Awards for offering an impressive portfolio of benefits for additive manufacturers during post-processing.
Beyond the surface:
Tackling the challenges of complex surface finish
Non-Destructive Testing (NDT) techniques can encounter challenges when dealing with a variety of surface finishes. The effectiveness of certain NDT methods, such as visual inspection or liquid penetrant testing, can be hindered by surfaces with complex textures, roughness, or irregularities. For example, surfaces with a high degree of reflectivity or glossy finishes may cause difficulties in visual inspection as they can create glare and obscure potential defects. Similarly, rough or uneven surfaces can impede the proper application and removal of liquid penetrant materials, affecting the accuracy of defect detection. Our Nonlinear resonance NDT technology is unaffected by surface finish meaning that we can successfully examine the internal structure of products made with a range of materials, from the surface roughness inherent of additive manufactured metals to the high reflectivity of traditional metals.
Game-changing NDT
Rapid non-destructive testing. Advanced flaw detection capabilities. Effortless operation. Empowering AM mass manufacture.
Unlock your manufacturing potential with nonlinear resonance NDT
With the rapid advancements and growing relevance of 3D printing for critical applications, employing a cutting-edge non-destructive testing solution is the key to your success. Look no further than our groundbreaking nonlinear resonance technology which offers unparalleled benefits, surpassing traditional NDT methods, and ensuring your parts meet the highest standards of quality and integrity.Â
Beyond the surface.
Tackling the challenges of complex surface finish.
Non-Destructive Testing (NDT) techniques can encounter challenges when dealing with a variety of surface finishes. The effectiveness of certain NDT methods, such as visual inspection or liquid penetrant testing, can be hindered by surfaces with complex textures, roughness, or irregularities and require smooth surfaces to deliver reliable test results. Similarly, rough or uneven surfaces can impede the proper application and removal of liquid penetrant materials, affecting the accuracy of defect detection. Our Nonlinear resonance NDT technology is unaffected by surface finish meaning that we can successfully examine the internal structure of products made with a range of materials.
Detecting the undetectable.
Uncovering hidden defects that other NDT methods cannot see.
Nonlinear resonance NDT has the capability to detect flaws and assess material conditions that other NDT techniques may struggle to identify. The technique can detect and characterize early-stage damage, such as microcracks or fatigue-induced defects, which may be too small or subtle to be detected by conventional linear NDT techniques. Nonlinear resonance is particularly sensitive to small defects or variations in material properties. Even minor changes in the material’s internal structure or properties can lead to observable nonlinear effects in the response signals. This sensitivity allows for the detection and differentiation of smaller or hidden flaws that may go undetected by other NDT methods.
Rapid precision.
Delivering fast, reliable, and accurate NDT results.
RD1-TT can deliver reliable pass/fail NDT test results in under one minute. This rapid NDT method allows for quicker inspection and evaluation of components or products. This leads to increased productivity by reducing inspection time and enabling faster turnaround in manufacturing processes. Manufacturers can streamline their production lines, minimize bottlenecks, and enhance overall operational efficiency. By reducing inspection time, manufacturers can also allocate resources more efficiently, optimize labour utilisation, and potentially reduce production downtime. Additionally, faster inspections can help identify defects or issues early in the manufacturing process, preventing further costly production of faulty components.
Self-referencing inspection.
Operate without the need for reference samples.
Our Self-referencing NDT technology means that a material or structure is used as its own reference or baseline for inspection and evaluation. Instead of comparing the test object to an external reference standard, self-referencing NDT relies on analysing changes or deviations within the material or structure itself. By eliminating the need for external reference standards, nonlinear resonance NDT can provide a more direct and accurate assessment of the condition and integrity of a material or structure. It allows for ongoing monitoring and detection of changes over time, enabling proactive maintenance or repair actions to be taken before significant issues arise.
User-friendly NDT.
Simplicity meets unparalleled efficiency.
We’ve simplified the non-destructive testing process, which means tests can be performed without the presence of highly skilled operators. The lack of requirements for non-specialised personnel reduces the need for hiring or outsourcing highly skilled engineers, which can be costly. Companies can allocate their resources more efficiently and potentially reduce overall inspection and maintenance costs. Nonlinear resonance NDT also makes it easier for a broader range of individuals to perform inspections and evaluations. This increased accessibility allows for wider implementation of NDT practices across different industries, including smaller businesses or organizations that may not have the resources to employ specialised personnel. Operators can be trained relatively quickly to perform a non-destructive test using RD1-TT and this allows for faster deployment of inspection procedures and enables prompt response to routine maintenance or quality control requirements.
Built for scale manufacture.
The perfect NDT solution for manufacturing at scale.
RD1-TT’s rapid test speed and streamlined operation make this the perfect solution for scale manufacturing. Where much slower NDT methods have reduced manufacturers to testing samples of the production, RD1-TT allows you to test 100% of manufactured parts. If you’re embracing additive manufacturing as your primary method, immediate post-printing inspection allows you to test 100% of parts prior to undertaking costly post-processing procedures; all but eradicating the possibility of adding value to defective components.
OUR VIDEO LIBRARY
Explore our expanding collection of video content designed to enhance your knowledge of Theta Technologies’ revolutionary NDT solution and keep you informed of our latest updates.Â
Featured Video
In this captivating interview with the CEO of Theta Technologies, Steve Butler, we dive into the world of additive manufacturing and explore the implications it has brought to the industry. This interview provides valuable insights into the transformative power of 3D printing and the crucial role of non-destructive testing (NDT) in ensuring the quality and reliability of increasingly complex parts. We unravel the impact of additive manufacturing on manufacturing decisions, the challenges it poses, and the innovative solutions Theta Technologies is bringing to the market.
Non-destructive testing
Case Studies
Discover how Theta Technologies’ revolutionary nonlinear resonance non-destructive testing (NDT) solution is benefitting manufacturers of metal, composite, and metal additive manufactured parts by exploring our expanding library of case studies.
NDT | Additive Manufacturing | Complex Parts
Unlocking the design potential of metal additive manufacturing with non-destructive testing (NDT).
The ability to create parts featuring increasingly complex geometries with additive manufacturing is an incredibly appealing factor, but existing non-destructive testing (NDT) techniques struggle to cope with the flexibility that 3D printing brings causing significant challenges for manufacturers of parts for safety-critical applications. Find out how Theta Technologies’ nonlinear resonance NDT technique can offer the solution for the additive manufacturing industry.
NDT | Turbine Blades | Creep
The rapid assessment of creep in nickel superalloy turbine blades with nonlinear resonance NDT.
Explore the significance of non-destructive testing (NDT) in safety-critical industries such as aerospace, automotive, and power generation. With even minor flaws compromising part integrity and posing risks, Theta Technologies’ nonlinear resonance NDT offers a rapid approach to flaw detection in turbine blades, potentially extending their lifespan and reducing maintenance costs. Dive into the potential of RD1-TT in ensuring component quality.
NDT | Additive Manufacturing | Star Artefacts
Nonlinear resonance NDT used to test additively manufactured star artefact samples.
Discover the challenges and solutions with non-destructive testing (NDT) for 3D-printed metal components. With traditional methods often proving inadequate for the testing of additive manufactured parts, Theta Technologies’ nonlinear resonance technology emerges as a beacon of hope. Discover how nonlinear resonance NDT, designed with additive manufacturing’s validation challenges in mind, can confidently test intricate 3D-printed components.
NDT | Additive Manufacturing | Flaw-detection
Nonlinear resonance NDT: offering a rapid flaw-detection solution for additive manufactured parts.
Additive manufacturing’s potential is vast, yet its youth compared to traditional methods has led to quality assurance challenges. Project RASCAL, an Innovate UK initiative, delves into the role of non-destructive testing (NDT) in ensuring the integrity of 3D-printed components. Theta Technologies’ RD1-TT emerges as the perfect solution, offering immediate post-printing assessments to detect flaws, ensuring the reliability of intricate designs.
NDT | Additive Manufacturing | Complex Parts
Addressing the challenges of non-destructive testing in complex additive manufactured parts.
In the rapidly advancing world of metal additive manufacturing, the quest for an effective non-destructive testing (NDT) solution remains. Heat exchangers, vital in automotive applications, epitomise the intricacy of 3D printed structures. Theta Technologies’ RD1-TT, with its nonlinear resonance NDT technology demonstrates its capability of handling complex metal AM designs and offering swift post-build evaluations.
NDT | PEEK | Tensile Stress Testing
Can NDT offer a more comprehensive quality assurance solution than tensile stress testing?
While tensile stress testing remains popular, its destructive nature poses challenges, especially with costly materials. Non-destructive testing (NDT) offers a promising alternative, preserving component integrity. Find out how Theta Technologies’ nonlinear resonance NDT is ideal for the testing of materials like Polyether Ether Ketone (PEEK) and how it can provide a more comprehensive quality assurance solution.
Join our waiting list for a
live demonstration of RD1-TT
Formnext 2023 | Additive Manufacturing
Attention additive manufacturers! Don’t miss the opportunity to witness the advanced capabilities of RD1-TT, Theta Technologies’ groundbreaking non-destructive testing solution. Join us for a live demonstration at the pinnacle of the additive manufacturing calendar, Formnext. As the future of manufacturing becomes increasingly complex, our solution promises to be a game-changer. Secure your spot on our waiting list and be among the first to experience the transformative power of RD1-TT in action.
Theta Technologies Limited
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Theta Technologies Limited
3 Babbage Way
Exeter Science Park
Clyst Honiton
Exeter
EX5 2FN
United Kingdom
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