Understanding What’s New in AWS D20

The American Welding Society (AWS) D20.1, Specification for Fabrication of Metal Components using Additive Manufacturing, first released in 2019, established a foundational framework for additive manufacturing (AM) processes and covered qualification, fabrication, and inspection requirements. Since then, the adoption of powder bed fusion (PBF) and directed energy deposition (DED) has grown rapidly across multiple industries, and with that growth comes the need for more precise and practical standards.

AWS D20.1 in Practice

Aerospace and defense technology company Northrop Grumman is a strong example of an organization effectively applying the original AWS D20.1 specification to qualify production PBF components across multiple business units. Their success stems from deliberately integrating the specification’s process‑
control, material‑verification, and part‑certification requirements into a broader, unified additive manufacturing strategy. This structured, standards‑driven approach has allowed the company to move PBF well beyond prototyping and into high‑value, mission‑critical applications (Ref. 1).

However, even with this success, it became clear that the original specification may require supplemental internal criteria and additional industry standards to be fully suitable across different sectors. Creating a single specification that spans multiple industries, while also covering fundamentally different additive processes such as DED (both wire and powder) and PBF, is inherently challenging. The volume of modifications or amendments needed for practical use contributed to the relatively limited adoption of the initial AWS D20 release and underscored the need to evolve the specification into a more flexible, broadly applicable framework.  

Evolution of AM Requirements

The AWS D20 Committee on Additive Manufacturing has been actively refining its approach to address industry feedback and evolving technical requirements. The original D20.1 specification was designed to apply broadly across AM processes, but as the technology matured, it became clear that material feedstock (powder vs. wire) required distinct considerations. To address this, the committee is now developing two separate specifications:

• D20.1: Maintained by the AWS D20A Subcommittee on Additive Manufacturing Using Powder, this specification will remain focused on powder-based AM processes.
• D20.2, Specification for Additive Manufacturing of Metal Components Using Wire Directed Energy Deposition: Currently being drafted by the AWS D20B Subcommittee on Additive Manufacturing Using Wire, this new specification will cover wire-based AM processes.

While both specifications share a similar philosophy for ensuring quality and compliance, the steps required for qualification and inspection differ significantly between powder and wire processes. This separation allows each document to be more specific, more applicable, and easier for industry to implement effectively.

For engineers and organizations planning to use these specifications, it’s important to note that both D20.1 and D20.2 demand a high level of technical understanding and input into the manufacturing process. These standards are designed to accommodate various material options and diverse applications, but they may require industry- or technology-specific requirements to ensure repeatable, reliable results.

Since the call to action in the November 2024 Welding Journal Standards Action story, “Additive Manufacturing Maintains a Prominent Presence in the Fabrication Field,” the AWS D20 Committee has grown by nearly 25%. This growth, coupled with active participation in the subcommittees, has not only increased industry awareness of the specifications but also amplified the influence of educators, end users, and producers on their development. With final review and acceptance underway, the updated specifications, both D20.1 and D20.2, are targeted for release in summer 2026. In the meantime, here’s a preview of some of the most significant updates you can expect in each.

AWS D20.1

The overall structure and requirements of AWS D20.1 remain largely consistent with the original draft. The most significant revision is the removal of wire‑based feedstock processes and the associated requirements. Process‑specific essential variables and acceptance criteria for both PBF and blown‑
powder DED have been updated to reflect the committee’s experience and feedback. Additionally, hardness testing requirements and further clarification on minimum defect‑spacing acceptance criteria have been incorporated based on input from both the committee and end users.

AWS D20.2

In the establishment of the new AWS D20.2 specification, the D20B Subcommittee increased reliance on established standards such as AWS B2.1, Specification for Welding Procedure and Performance Qualification, and placed greater emphasis on engineering control throughout the document such that the specification could be effectively applied across multiple industries and use cases. By anchoring D20.2 in well‑defined, industry‑proven frameworks, the committee aimed to streamline qualification and inspection requirements without compromising rigor or broad applicability. Building on this foundation, the proposed updates introduce several key enhancements:

• Responsibility for determining nondestructive examination methods and acceptance criteria now resides with the engineer, supported by example criteria appropriate for various applications.
• Procedure qualification adapts essential variables from AWS B2.1 to reflect specific DED process types, and the overall qualification approach aligns with methodologies used by ASME Boiler and Pressure Vessel Code, Section IX, and NAVSEA, allowing manufacturers to qualify a general performance envelope suitable for the inherently dynamic nature of DED.
• The allowable production component size is tied to the qualification coupon dimensions, providing a scalable and defensible path for production work.
  Structured requirements specific to qualifying wire DED additive machine operators have been added.

Conclusion

With the release of the updated AWS D20.1 and D20.2 specifications approaching, the committee’s work is far from over. As the AM industry continues to rapidly evolve, so must the standards that support it. This refinement depends on active participation from practitioners who use these documents every day.

The D20 Committee welcomes new members (manufacturers, users, educators, and general interest members) who can contribute technical insight, identify opportunities for improvement, and help ensure future revisions remain practical, relevant, and forward looking. Those interested in shaping the next generation of AM standards are encouraged to reach out and get involved. Please contact AWS Program Manager Exsenet Esler at eesler@aws.org.

References

1. Tryer-Jones, A. AMAA 2025: 90% cost and time savings at Northrop Grumman enabled by 3D printing. 3D Printing Industry. 3dprintingindustry.com/news/amaa-2025-90-cost-and-time-savings-at-northrop-grumman-enabled-by-3d-printing-242304

2. Northrop Grumman. Space systems additive manufacturing: Defining possible with space additive manufacturing for more than 20 years. northropgrumman.com/what-we-do/space/space-systems-additive-manufacturing

BRAD BARNHART (bbarnhart@lincolnelectricfederal.com) is engineering manager, The Lincoln Electric Co., Euclid, Ohio.