Metallography labs are essential laboratories that analyze, develop, and perform quality assurance of metal components used in aerospace, automotive, medical, defense, and construction industries. When designing or furnishing this kind of lab, it’s important to have a solid foundation to aid you in a smooth process. In this blog, we will discover to to design one, the basics about metallography and provide insight the best practices and best kind of furniture to have as well.
What Is Metallography?
Before beginning with design, we must understand the field of study.
Metallography is the study of the microstructure of metallic alloys and materials using various techniques, including sectioning, mounting, grinding, polishing, and microscopic examination. These observations help determine grain size, phase distribution, inclusions, and structural integrity. Metallographic analysis can also reveal potential failures or quality issues in materials before they reach the field.
Some applications include quality control, failure analysis, process validation, and R&D across nearly every manufacturing industry.(Source: ASM International)
Why is Metallography Important?
Designing a great metallography lab isn’t just about organization, that’s only one part. The design directly impacts the accuracy, repeatability, and speed of the laboratory’s testing process.
Benefits of a well-designed metallography lab to are:
- Reliable, contamination-free sample prep
- Workflow efficiency from start to finish
- Consistency with ASTM and ISO standards (e.g. ASTM E3, ASTM E407)
- Reduce outsourcing and faster turnaround for results.
Essentially, the field of metallography is to help in failure prevention, quality control (qc) , and innovation, especially in high-risk industries where materials performance is non-negotiable.
Guiding Design Pricniples for Metallography Labs
Design Principle
Why It Matters
Practical Tips
Unidirectional Workflow
Keep samples moving cleanly from dirt to clean zones, reducing contamination
Layout stations in the order: sectioning → mounting → grinding → polishing → etching → imaging
Zoned Layout
Segregates loud, dusty equipment from clean analysis areas
Place abrasives saws and grinders away from microscopes: use partitioning where possible
Chemical Safety
Etchants nitric of hydrochloric acid are hazardous
Include ducted fume hoods, acid and chemical resistant work surfaces, and proper laboratory cabinet storage
Vibration Control
Essential for accurate microscopy and image clarity
Locate microscopes away from foot traffic and grinders; use anti-vibration tables
Modularity
Allows easy upgrades and layout adjustments
Choose mobile lab tables and flexible lab set ups that can be easily reconfigured.
Proper Ventilation
Prevents fumes, heat buildup and harsh dust
Install localized exhaust (snorkels) for saws, polishers, and etching stations
Lighting & Environment
Prevents visual fatigue and supports consistent imaging
Use dimmable LED task lighting and maintain climate control in microscope rooms
Seven Key Areas to Include in Your Metallography Lab Design
In metallography labs, these are important areas to have (you are not limited to only these areas):
1. Sample Receiving and Storage
First, dedicated sections with epoxy resin or phenolic resin worksurfaces and shelving to house unprocessed samples.
2. Sectioning and Cutting
Secondly, have metallographic saws and splash guards. Install ventilation or mist collection systems and ensure these are away from clean zones.
3. Mounting
Next, presses, whether hot or cold, should sit on heat and chemical resistant surfaces like epoxy resin countertops or stainless steel. Phenolic resin can work here but if the area direct heat or will repeated heat over the course of long periods, then phenolic is not recommended. Have molds, cups and resin within arms reach.
4. Grinding and Polishing
Fourth, in this section, you’ll have wet polishers and abrasive stations. These need waterproof cabinetry (powder coated metal, stainless steel, phenolic resin or polypropylene), chemical resistant inks, and durable drainage. Vibration isolation in this area helps maintain consistency.
5. Etching and Cleaning
Fifth, have ducted fume hoods and chemical resistant countertops and worksurfaces and eye wash stations are essential for acid-based etching.
6. Microscopy and Imaging
Sixth, microscope rooms should be quiet, dark, and free from vibration for precise analysis. Microscope and anti-vibration tables with adjustable height capabilities provide vibration control and easy height adjustments among lab personnel. As well as, having blackout shades and task lighting helps too.
7. Digital Analysis and Archival
Finally, section off a technical desk or corner for imaging software, data review and archiving. Store backup images securely in this area.
Equipment in Metallography labs
Zone
a. Sectioning
b. Mounting
c. Grinding/Polishing
d. Cleaning
e. Etching
f. Microscopy
g. Safety
Equipment Pieces
a. Abrasive or low speed saws
b. Hot-mount presses, cold-mount systems
c. Semi-auto polishers, diamond suspensions
d. Ultrasonic cleaners, rinse sinks
e. Etchant containers, fume hoods, PPE
f. Metallurgical microscopes, SEM with EDS
g. Eyewash stations, chemical cabinets, fire extinguishers
Safety and Compliance
As mentioned before, metallography laboratory design aren’t just about workflow optimization and efficiency, safe is of utmost importance. It’s necessary to have:
- Ventilation: Ducted fume hoods over etching stations and saws
- Eyewash & Showers: ANSI Z358.1-compliant fixtures
- Chemical Storage: Use clearly labeled, vented acid cabinets; avoid storing hydrofluoric acid in glass.
Conclusion
All in all, a metallography laboratory is more than a lab environment. It’s a tool for discovery, qc (quality control) and innovation. From various workflow zoning to safety infrastructure and compliance to modern instrumentation and lab furniture setups, a thoughtful and carefully curated lab design ensures repeatability, high-quality results and long-term adaptability.
Neeed Help Designing Your Metallography Lab?
To better understand how these factors com together, at OnePointe Solutions, designing labs is our expertise. Whether a you’re small public city or county lab or a multi-building facility for a corporate conglomerate, we can help you where you are. In addition, we have an artillery of architects, lab planners and general contractors all experienced in lab construction and consulting that can help you navigate the laboratory landscape to ensure your space is compliant, built and furnished correctly. Give us a call today to get started – 866-612-7312