Beyond the Spreadsheet: Why Specialised Additive MES is Vital for Audit Traceability

In the world of regulated manufacturing - aerospace, defence, and medical devices - the phrase "good enough" doesn't exist. When a part fails in the field, the ability to trace its history isn't just a matter of operational efficiency; it is a safety mandate.

As companies scale their Additive Manufacturing (AM) from R&D into full-scale production, many attempt to manage their shop floor using legacy Manufacturing Execution Systems (MES) or, more commonly, a complex web of Excel spreadsheets. However, additive manufacturing introduces unique variables that traditional systems were never built to handle.

Here is why a general MES fails the additive audit trail, and how an AM-specific digital thread ensures compliance and quality.

1. The "Material Genealogy" Gap

In traditional CNC machining, you start with a solid block of certified material. In additive manufacturing, you are often creating the material at the same time you are shaping the part.

A general MES sees "Powder" as a static inventory item. Authentise, however, recognises that powder is dynamic. Our Digital Material Genealogy module tracks:

• The Reuse Cycle: How many times has this specific batch of Ti64 been through the printer?

• Blending & Sieving: Automatically recording when virgin powder is mixed with recycled batches.

• The "Family Tree": Linking every part back to its specific chemical batch and its precise location in the build chamber.

Without this granular tracking, a manual log failure rate can exceed 30%, leaving gaps in your compliance records that could lead to costly non-conformances.

2. Capturing the "Birth Certificate" of a Part

An audit-ready digital thread requires more than just knowing a part was printed. It requires a comprehensive "Birth Certificate" that connects:

• Machine Telemetry: Real-time data pulled directly from the printer (O2 levels, laser power, chamber temperature).

• Operator Actions: Who loaded the powder? Who performed the post-processing? Authentise uses QR-based tracking and mobile apps to capture these human touchpoints in real-time.

• Post-Processing & Inspection: Additive parts often undergo heat treatment, HIP, or CNC finishing. A general MES often loses sight of the part once it leaves the "primary" work centre. An AM-specific workflow ensures every secondary operation is logged within the same digital record.

3. From "Tribal Knowledge" to Standardized Compliance

Many AM facilities rely on "tribal knowledge" - the specific expertise of a few key engineers. When scaling to multiple sites, this reliance becomes a liability.

Authentise solves this by digitising Standard Operating Procedures (SOPs) directly into the workflow. Operators are guided through enforced controls, ensuring that whether a part is printed in London or Los Angeles, the process - and the resulting data - is identical. This level of standardization is foundational for achieving certifications like AS9100 or ISO 13485.

4. Audit Readiness in Seconds, Not Weeks

When an auditor asks for the history of a specific medical implant or aerospace bracket, how long does it take your team to find it? If you are digging through filing cabinets or searching for the right version of a spreadsheet, you are at risk.

With a digital MES like Authentise, the audit trail is generated automatically as work happens. Reports that once took weeks to compile manually can be retrieved in under 10 seconds.

Conclusion: The Cost of the Status Quo

The risk of using an inadequate system isn't just administrative; it's financial and reputational. A single quality management error can cost millions in recalls and legal fees.

By moving beyond the spreadsheet and adopting an MES built for the realities of additive manufacturing, you aren't just checking a compliance box - you are building a foundation for a scalable, data-driven future.

Ready to see how the digital thread can secure your workflow? Explore our Data, Software, and Workflow in Additive Manufacturing Post to learn how Authentise connects the dots from design to delivery.