What's new previous versions
Top new features and highlight of previous Simufact Additive releases.
Top features of the previous Simufact Additive releases
Do you want to know which key features we have implemented in the previous versions? Scroll down on the website and familiarize with the top new key features of each respective versions. Please note that we concentrate on key features of the latest three versions.
Top New Features in Simufact Additive 2020
Top New Features in Simufact Additive 2020
- Cost estimation for the entire build process
- 3MF interface
- Integrated build job preparation and export
Cost estimation for the entire build process
With the release of Simufact Additive 2020, Simufact is expanding the scope of its simulation tool: From now on, users cannot only design and optimize the build process virtually, but rather make an immediate cost estimation for several, as well as individual, components of printing processes in advance. In addition to the build process, the functionality also includes all downstream processes such as cutting and subsequent processes.
With the cost estimation the user is able to gain insights into the estimated costs of the build process based on individually adjustable partial costs. The orientation assistant also provides answers to the expected costs for a given orientation. If the user changes the orientation, the software automatically determines the new costs. With just one click, the user can transfer a detailed list of the estimated costs to Excel. Furthermore, the user can compare the expected costs of a single printing process versus one with multiple components.
3MF interface enables bi-directional data exchange between Simufact Additive and Materialise Magics
Simufact Additive 2020 provides users with the 3MF interface, an industry standard 3D printing format for import and export. This interface enables simple and reliable data transfer to third-party software such as Materialise Magics. In addition, Simufact underlines its open-mind attitude towards third-party products. Furthermore, the 3MF interface considerably improves the model set up in conjunction with Materialise Magics.
Integrated build job preparation and export
Version 2020 not only extends its scope of a pure process simulation solution, but also allows users additionally to integrate build job preparation with a direct export function to Renishaw printers/machines. The laser paths for all layers can now be created and visualized so that the user can identify possible problems in the printing process at an early stage. With this function, Simufact Additive 2020 completes the process chain concept with a further function that allows error-free data transmission and thus also makes the entire work process more efficient. Simufact Additive 2020 thus creates framework conditions that can also be of interest to other printer manufacturers.
CAD-Interface provides seamless import and export of data
Currently the loop from the CAD model, over the CAD import to the simulation and back to the CAD model is open, as there is no possibility to export simulation results such as compensated geometries into native or neutral CAD formats (STEP, etc.). This discontinuity in the process chain will be closed with the new CAD export. The CAD export of the geometries, originally from a CAD system, and compensated or distorted by Simufact Additive can be exported again into native and neutral CAD files.
These files can later be used for CAM simulations and further processing in CAD programs. The time-consuming and inaccurate manual reconstruction of these geometries is eliminated.
Adaptive voxel meshing
With adaptive voxel meshing, Simufact Additive 2020 automatically adjusts the voxel sizes in the part. Thus elements can be coarsened or refined if needed. This adaptation improves the simulation speed and thus, in turn, provides the simulation results faster. In addition, the new functionality also has a stabilizing effect on the simulation and thus makes it even more precise.
Hybrid manufacturing: Combine additive with conventional manufacturing
Hybrid manufacturing combines the additive manufacturing process with conventional manufactured parts, e.g. a printed drill head with a special contour on a conventional manufactured drill body. Hybrid manufacturing arises new questions on stresses and distortions of the complete assembly as well as of every single part. Also, combinations of different materials can be interesting to investigate. The new version allows defining parts as “starting points” on which the printing will start. Thus, stresses and distortions of the complete assembly and all single parts can be investigated.
Top New Features in Simufact Additive 3.1
Top New Features in Simufact Additive 3.1
- Orientation assistant to determine the best build orientation
- Automated distortion compensation
- Identification of manufacturing issues
- ...
Orientation assistant to determine the best build orientation
The new orientation assistant supports the user during model set up. This new function offers a striking view of the build orientation, which makes the evaluation easier and more intuitive.
This function is based on 5 criteria, which are balanced among each other:
- Support area
- Support volume
- Projected area
- Design height
- Local minima
Users determine the best build orientation by selecting one or more criteria which are most suitable for their process. The assistant displays the results for the component alignment in the form of a sphere. The colored illustration (green to red) shows the user how good or bad the component alignment is within the selected criteria. By clicking on the sphere, the part is automatically rotated in to the corresponding build orientation. This interactive and intuitive handling enables the user to get a preview of the build orientation. It is also possible to use this functionality with multiple parts, but the user needs to adjust every single part.
Automated distortion compensation
The automated distortion compensation helps users to optimize the distortion of the part and save time even easier and faster. Two steps need to be taken beforehand:
The user must
- select the function and
- specify the tolerable deviation.
Once this is done, the software automatically calculates the deviation of the manufactured part to the initial part – based on a “best fit method”. This process is repeated several times. After 3-5 iteration steps, the user receives a geometry that shows minimum deviations to the initial part. Simulations with multiple or complex parts are possible as well but naturally will need more time.
During the deviation calculation the user is still able to work on additional projects in the software.
This new feature is essential since virtual distortion compensation replaces time consuming and costly try-outs.
Identification of manufacturing issues
This function consists of three methods that support the user while evaluating the results. Overall, all three functions enable the user to identify critical areas in the part.
- Recoater Contact: It indicates the probability of contact between recoater and part.
- Possible Part Failure: A traffic light system indicates how likely it is that the part cracks while printing.
- Layer Offset Intensity: During the printing process it is possible that a layer offset occurs. The layer offset is a change in the powder bed which can lead to a surface defect of the part. Employing this function helps the user to identify critical areas of the part.
Particle tracking to create history plots and advanced path plots
Particle tracking to create history plots and advanced path plots enables the user to identify the material properties and material states in the different layers of a printed part over time. Applying the powder bed layer by layer can cause changes in the underlying layers due to heat influences of the laser. These can now be visualized with the particle tracking. In addition, a path plot function is available which allows the user to plot results not over time but over the distance between the particles.
Top new features in Simufact Additive 3
Top new features in Simufact Additive 3
- Thermo-mechanical calculation method
- Version 3 predicts influences of base plate on the component
- Simulation on Linux machines and Linux clusters
- ...
Thermo-mechanical calculation method
In addition to the proven pure mechanical inherent strain method Simufact implemented in version 3 a thermo-mechanical calculation method. The build process is simulated layer wise by a thermo-mechanical method. It allows users to make statements at an early stage about global thermal behavior in the part, for example, to detect thermal peak loads. This method is physically more comprehensive, since real machine parameters are used, including thermally relevant parameters such as laser power, laser speed and predetermined temperatures in the construction chamber. This brings the simulation closer to the familiar manufacturing process.
Version 3 predicts influences of base plate on the component
During the additive manufacturing process, distortions and residual stresses occur both in the workpieces and in the base plate. The latter can affect the properties of the support structures and the component. With Simufact Additive 3 you can determine the influences of the base plate. As a practical application, the user for instance may determine when the base plate has become too thin and an exchange is required.
Simulation on Linux machines and Linux clusters
Simufact Additive 3 offers a Linux solver in addition to the Windows Solver. Thereby the software is now available for simulations on Linux computers for instance on high performance Linux clusters. The operation of the software through the GUI continues in the Windows environment
Multiple Parts: Simultaneous simulation of several components in the build space
In practice, several geometries are usually arranged and printed in the build space simultaneously. With Simufact Additive 3, the user quickly and easily models the thermal printing process of several geometries in the build space and recognizes at which point the components influence each other.
Best-Fit method: By touch of a button compare simulation and reference model
In Simufact Additive 3, users can compare simulation results and reference model (e.g., CAD data) by mouse click using "best-fit" positioning. In the best-fit method, the software automatically determines the position at which the deviations are lowest. The visual presentation of the results, based on measurements, allows the user to quickly assess whether the deviations are within the permissible tolerances. For this function, Simufact has integrated Hexagon's 3DReshaper technology.
Top new features in Simufact Additive 2
Top new features in Simufact Additive 2
- Calibrating with Cantilevers (physical testing)
- Individual positioning of parts in virtual build space
- Support of orthotropic material properties
- ...
Calibrating with Cantilevers (physical testing)
In addition to the proven pure mechanical inherent strain method Simufact implemented in version 3 a thermo-mechanical calculation method. The build process is simulated layer wise by a thermo-mechanical method. It allows users to make statements at an early stage about global thermal behavior in the part, for example, to detect thermal peak loads. This method is physically more comprehensive, since real machine parameters are used, including thermally relevant parameters such as laser power, laser speed and predetermined temperatures in the construction chamber. This brings the simulation closer to the familiar manufacturing process.
Individual positioning of parts in virtual build space
Simufact Additive 2 provides special handling to determine the most efficient positioning of parts on the base plate and allows for iterations to be made that optimize the build-up-orientation. Positioning the part is very intuitive, due to the easy-to-use-interface.
Support of orthotropic material properties
Simufact Additive 2 takes into account orthotropic material properties, which enables a more realistic representation of support structures stiffness. Coarser meshing provides reliable results with a simultaneous reduction of the required calculation times.
Variants simulation: Optimize the additive process chain more effectively
An effective, fast optimization of the entire process chain, including printing, heat treatment, cutting/removing of supports, and HIP. With Simufact Additive 2, users are now able to stop and re-start the simulation process at any stage of the process chain. Each process step can be optimized separately based on the previous results. Simufact Additive 2 further shortens the simulation calculation times.
Simulate HIP processes
Simulating the HIP process (Hot Isostatic Pressing) in Simufact Additive 2 now includes the parts porosity and its densification – based on the hollow-sphere model. The component density affects the product lifetime, which can be significantly longer, the less porous the work piece is.
Comparison with physical testing
Simufact Additive 2 enables users with a comparison of simulated parts with the target design or 3D measurement data as a reference. Users can also evaluate deformations relative to the reference geometry. Users can measure the actual part and import the results into Simufact Additive. This ultimately provides engineers with an easier way to compare their results, which ensures a more efficient workflow.
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