Traceability in Additive Manufacturing: Why Aerospace Still Struggles - and How to Fix It

Introduction — Additive Manufacturing Needs Traceability More Than Any Other Process

Additive manufacturing (AM) is used for some of the world’s most demanding applications:

• aircraft structures,

• propulsion systems,

• satellite components,

• medical implants.

Yet despite the criticality, most AM supply chains still struggle with traceability.

Why? Because AM isn’t just a manufacturing method - it’s a data-intensive, multi-stage digital process where every step matters.

But too often:

• data lives in separate systems,

• material logs rely on spreadsheets,

• machine data disappears into folders,

• testing documents stay in email chains,

• design revisions float around uncontrolled.

The result is a fragmented digital trail that can’t withstand aerospace-level audits.

This article explains why traceability is so difficult in AM and what a complete, scalable solution looks like.

For foundational reading, see: Additive MES Explained

Why Aerospace Still Struggles With AM Traceability

Aerospace production requires a complete, unbroken lineage of every part ever manufactured.But additive manufacturing introduces complexity that traditional traceability frameworks were not designed to handle.

1. Too Many Data Sources, Not Enough Connection

AM requires traceability across:

• design files

• slicing parameters

• build logs

• machine sensor data

• powder batches

• re-use cycles

• external testing

• heat treatments

• certifications

Each of these often lives in a different system - or worse, in email attachments.

2. Material Genealogy Is Hard (But Critical)

Powder handling alone creates dozens of traceability events:

• blending

• sieving

• transfers

• weighing

• drying

• reuse

• returns

• disposal

If even one step lacks documentation, the entire genealogy collapses.

See also: Future of Material Management

3. Machine Data Isn’t Standardised

Every OEM exports logs differently.Some include thermal maps, some exclude parameter drift, some encrypt data, some provide APIs… many don’t.

This inconsistency disrupts any attempt at unified traceability.

4. Post-Processing Adds Even More Complexity

Steps include:

• machining

• heat treatment

• HIP

• blasting

• finishing

• coating

Each step must be tied back to the originating build.

5. External Labs Are the Biggest Blind Spot

Aerospace qualification relies heavily on:

• tensile tests

• CT scans

• metallography

• surface measurements

But labs typically send PDFs by email, which:

• aren’t structured

• aren’t linked

• aren’t searchable

• aren’t integrated

This breaks the digital thread.

What Complete Traceability Looks Like

Aerospace-ready traceability includes every piece of data, captured automatically, tied to the part, stored securely, and accessible on demand.

Here’s what "good" looks like:

1. Centralised, Controlled Design Data

No more:

❌ files saved on desktops

❌ email attachments

❌ uncontrolled revisions

The correct version is always traceable.

2. Full Material Genealogy

This includes:

• batch certificates

• withdrawal and return logs

• re-use cycles

• blending records

• storage location

• expiry dates

Material = risk.And aerospace requires proof of control at every step.

3. Machine Data Ingestion Into the Workflow

Build logs must be:

• automatically captured

• contextualised

• linked to the right part

• viewed alongside operator notes

This captures the process signature of every build.

4. Complete Post-Processing History

Every downstream step becomes part of the digital record.

This aligns with lessons learned in programmes such as: MABOND Case Study

5. Linked, Structured Test Data

Instead of isolated PDFs, test results flow into the central system and attach directly to the part lifecycle.

This is increasingly required across industry programmes like: DECSAM Programme

Why Traceability Is Becoming a Hard Requirement

The shift toward digital-first certification is accelerating.

Aerospace primes and regulators are now requiring:

• complete digital thread

• documented testing

• machine-process linkage

• automated traceability

• data integrity

• part provenance

The days of "reconstructing traceability during audits" are over.

How to Build Audit-Ready Traceability in Additive Manufacturing

A robust traceability framework rests on four core pillars:

Pillar 1 — Capture Everything, Automatically

Humans forget. Machines don’t.

Automation ensures no step is overlooked.

Pillar 2 — Connect All Data Into a Single System

If data stays in silos, traceability collapses.

Pillar 3 — Maintain a Continuous Digital Thread

Every action should be linked: design → material → build → post-processing → test results → final certification.

See: Smart, Traceable, Efficient

Pillar 4 — Make Traceability Easy to Use

If a system requires effort, humans won’t follow it.

Successful solutions:

• auto-fill forms

• sync machine data

• pull from existing sources

• integrate results

• generate traceability reports automatically

H2: The Business Impact of Proper Traceability

Traceability isn’t just a regulatory checkbox - it’s a performance driver.

Compliance Confidence

Audits can be passed in minutes, not weeks.

Faster Root Cause Analysis

Failures can be traced instantly.

Reduced Scrap & Rework

Material misuse and parameter drift are caught early.

Accelerated Qualification

Evidence packages are generated automatically.

Supply Chain Predictability

External partners become trustworthy contributors.

Conclusion — Traceability Is the Backbone of Industrial AM

Aerospace and defence cannot rely on fragmented traceability. Complete digital lineage is essential for:

• certification

• repeatability

• risk reduction

• quality assurance

• customer confidence

Additive manufacturing becomes truly industrial only when traceability becomes automatic, integrated, and complete.

Recommended Authentise Tools

• Authentise Threads - test data, documentation, and supplier traceability

• Authentise Flows - workflow & end-to-end digital thread

• Materials Management - powder lifecycle & full material genealogy

• Digital Design Warehouse - version-controlled design lineage

Ready to Build End-to-End Traceability?

See how leading aerospace organisations are using Authentise to build unbroken digital threads. Book a demo