SIMUFACT ADDITIVE

CAE tool for Metal 3D Printing / Rapid Prototyping

OVERVIEW

Do you want to… ... calculate the deformation of the final part ... analyze the residual stresses? ... optimize the build-up orientation? ... improve the support structure? ... reduce material and energy consumption costs?

 

Simufact Additive is a scalable software solution for the simulation of metal-based additive manufacturing processes which focuses on powder bed melting processes.

With the macroscopic approach, users obtain simulation results within minutes that predict the tendency of stresses and distortions. Furthermore, thermal or thermo-mechanical calculations can be performed to obtain precise results which consider the temperature distribution during the process.

Simufact Additive is a software solution designed to predict and compensate for distortion, residual stress and temperature distribution throughout the printing, heat treatment, cutting and HIP processes virtually before the part is manufactured by the 3D metal printer in reality.

Additional modules are available for all Simufact software solutions to help with microstructure calculations, faster performance, additional CAD import interfaces, customization, and access to material databases.

 

SIMUFACT ADDITIVE - CAPABILITIES

 

• Best-in-class solution for manufacturing processes

• Forming applications

• Joining applications

• 3D-metal-printing applications

• Pre- and post-processing environment dedicated to manufacturing processes

• Accurate material description

• Prediction of part properties during the manufacturing process chain

• Open architecture

• Strong solver able to solve simple to the most advanced manufacturing problems

• Integrates the most advanced technologies for best accuracy

 

BENEFITS

• Best-in-class result accuracy at highest speed & stability

• Scalable solutions

• Cost optimized

• All relevant manufacturing process stages with full interoperability

• Simple process-oriented setup of the process

• Supported by a team of manufacturing experts

• Developing an efficient forming method in a short span of time without blocking the machine for testing

• React fast and better and flexible on new demands

• Controlling temperature and machine force

 
 

HIGHLIGHTS

 
 

Compensate Distortions

  • Calculate the final part distortion

  • Automated distortion compensation

  • Distortion compensation throughout the entire process

 

Optimize Support Structures

  • Automated generation of optimized support structures

  • Simufact Supports

  • Materialise-based support structures

  • Consideration of different stiffnesses in the support structures

  • Support of orthotropic material properties

 

Identify Manufacturing Issues

  • Specific manufacturing issues

    • Identify contact between recoater and component

    • Identify possible part failure (e.g. through cracks). These occur due to excessive internal stresses or plastic strain

    • Identify layer offset intensity

  • Evaluation of spatially dependent parameters of results in diagrams

    • Calculate the local peak temperature

    • Predict melting points that are too low

    • Identify overheating in the component

    • Optimise support structures for temperature control

 

Compare and understand Simulation Results

  • Description of geometry deviation

    • To the target geometry (CAD)

    • To physical tests / 3D-measurement

  • "Virtual Metrology“

    • Best-Fit or manual positioning of target and calculated geometry

    • Represent the normal distance of the surfaces

  • Export functionality / Transfer of simulation results

    • Distortion compensation of a pre-formed

    • Export of pre-formed CAD geometry

    • Results on 3D solids, e.g. for structural analyses

 

Minimize Residual Stresses

  • Calculate and minimize residual stresses

 

Build Space: Positioning and Nesting

  • Determine influences of base plate heating on the components

  • Multiple Parts: Simultaneous simulation of several components in the installation space

  • Optimize the number and positions of the components in the build space

  • Influence of the base plate (distortion) including pre-heating

 

Additive Manufacturing-Process Chain

  • Determine the influence of post-processing steps

  • Determine Heat Treatment to reduce stress

  • Optimize cutting parameters

  • Simulate Hot Isostatic Pressing (HIP): Analyze the relative density during HIP process

  • Simulate various processes: Optimize the additive process