Simulating Additive Manufacturing with Simufact Additive

Learn more about the potential of process simulation in Additive Manufacturing

Discover how Simufact Additive, our solution for additive manufacturing simulation, helps you optimize metal additive manufacturing and rapid metal prototyping.

Introducing Simufact Additive

Insights into Simufact Additive capabilities


Simufact Additive 4 is available now

Aviable soon  Simufact Additive V4

New version convinces with automatation and assistant functionality for a even better ease-of-use of the software.

Learn more

Webinar on demand: Introduction Simufact Additive

Webinar Icon

Gain first insights into the additive manufacturing simulation and listen to our 30-minutes overall webinar introducing Simufact Additive 4.

Register here



Interview with Dr. Hendrik Schafstall, Simufact CEO

In an interview with Stefaan Motte, Vice President Software of Materialise Software, Dr. Hendrik Schafstall explains the value simulation can bring to Metal 3D Printing, what it means to have simulation integrated within Materialise Magics and what the future of simulation looks like.

Key Benefits summary


Simufact Additive is a powerful and scalable software solution for the simulation of metal additive manufacturing processes or also known as rapid prototyping metal simulation.

Simufact Additive helps you produce AM parts first-time-right:

  1. Calculate the deformation of the final part incl. the base plate
  2. Compensate distortions by pre-deformation of the part - automatically
  3. Calculate and minimize residual stress
  4. Identify cold and hot spots due to thermal/thermo-mechanical simulation
  5. Identify manufacturing issues such as recoater contact, part failure and layer offsets
  6. Predict the influence of several components in the build space
  7. Determine the best build orientation - supported by an orientation assistant
  8. Generate and optimize supports - based on Materialise technology
  9. Examine conditions of highly elevated temperatures and pressures - HIP process
  10. Condition of the part also after heat treatment, base plate and support structure removal
  11. Run the simulation in Windows and Linux environment

In the future also

  1. Predict the microstructure
  2. Indicate criteria-based part failure

Achieve your business goals with Simufact Additive

Replace time-consuming testing with simulation methods!

Employ Simufact Additive process simulation and save time and money:

  1. Shorten your learning process dramatically
  2. Run more variations prior to the production
  3. Shorten time-to-market
  4. Increase machine/manpower availability and productivity
  5. Reduce material and energy consumption costs

5 reasons why ...

Five reasons why ...

... Simufact Additive will lead the way.

Simufact Additive brochure

Simulating Reality magazine

Virtual Reality Magazin - thumb

MSC's Simulating Reality magazine introduces new simulation solutions for Plastics and Metal additive manufacturing technologies, showcasing real examples and providing insights into what´s coming next in AM simulation – from MSC´s e-Xstream and Simufact.


Functional Scope of Simufact Additive

Powder Bed Fusion

Powder Bed Fusion
Powder Bed Fusion

Laser Metal Deposition

Icon Laser Deposition
Deposition Methods

Simufact Additive covers the simulation of Powder Bed Fusion processes, e.g. known as:

  • Selective Laser Melting (SLM)
  • Direct Metal Laser Sintering (DMLS) - an EOS technology
  • LaserCUSING® - a Concept Laser technology
  • Electron Beam Melting (EBM) - an ARCAM technology
  • and more …
Laser Beam Melting principle with machine scheme (Source: Fraunhofer IWU)
Laser Beam Melting principle with machine scheme (Source: Fraunhofer IWU)

Please note that the simulation of Laser Metal Deposition (LMD) processes is covered by Simufact Welding.

  • Direct Metal Deposition (DMD)
  • Directed Energy Deposition (DED)
  • Laser Cladding


Simufact Welding for Laser Metal Deposition
Simufact Welding for Laser Metal Deposition

Additive Manufacturing Process Chain

AM process chain vision

Covering the complete AM process chain (in combination with MSC products)

Additive Manufacturing process chain
Additive Manufacturing process chain covered by MSC & Simufact

Embedded process chain simulation

Simufact Additive covers the core manufacturing process chain including

  • Additive Manufacturing
  • Heat Treatment / stress relief process
  • Cutting & removal of the support structures and plate
  • HIP process (hot isostatic pressing) prediction of distortion, residual stress and material densification


Read more about MSC´s complete AM solution portfolio:

MSC Solutions for Additive Manufacturing


AM Simulation videos - Examples

Simulation of distortion of an additively manufactured manifold

Simulation of effective stress of an additively manufactured aerospace bracket

Your Benefits: Simufact Additive helps you

Calculate the deformation of the final part

  • Detect and minimize too high distortion in the height to avoid build job abortions
  • Recalculate pre-distorted shape, so that distortion can be compensated
App. Total distortion in an AM created bracket
Total distortion in an AM created bracket

Minimize residual stress

  • Avoid build job abortion
  • Avoid subsequent cracking

Explore impact of manufacturing post-processing steps

  • Heat treatment - Prediction of distortion and residual stress under the conditions of highly elevated temperatures and creep effects
  • HIP - Prediction of distortion, residual stress and material densification (e.g. based on the hollow sphere model) under the conditions of highly elevated temperatures and pressures
  • Removal operations (base plate and support structures)

Optimizing the process chain: This picture sequence illustrates the stepwise reduction of residual stress in a bracket during the manufacturing post-processing steps. The result of the optimization process is an almost stress-free bracket.

Optimize the build-up orientation

  • Compare different options for build-up orientation
  • Find the optimal build strategy

Optimize support structures

  • Determine the minimum needed support structures
  • Check influence on deformation and stress
  • Analyze influence of different support designs and their properties

With friendly permission by NDES.

Optimize cutting parameters

  • Compare simulation results of different cutting strategies
  • Minimize the final distortion



More options

Accuracy and speed of simulation

Multi-scaling approach

Simufact Additive´s basic concept lays the foundation for a wide variability and scalability through different levels of details for the simulation results. Simufact Additive combines best approaches in one unique software solution.

We call this a multi-scaling approach:

  • Macroscopic approaches
    • Fast layer-based models using inherent strains method
    • An extremely fast mechanical method for the prediction of distortion and residual stresses in the component  / base plate
    • A thermo-mechanical method for the prediction of global heat distribution, distortion and residual stresses in the component and base plate
  • Mesoscopic approach (upcoming versions)
    • Intermediate approaches combining the advantages of reasonable analysis times and the desired level of detail
    • Hatching model, e.g. with inherent strain or thermal cycle
  • Microscopic approach (upcoming versions)
    • A fully thermo-mechanically coupled transient analysis to accurately determine the temperature history and derived properties like the microstructure.
    • Heat source model
    • High level of detail, based on multiphase models



Running a fully thermo-mechanically coupled transient analysis will provide highest result accuracy - but is this your daily business?

Often a faster approach might be sufficient - which helps you achieve short-term analysis results to guide your day-by-day decision making.

Improved solver technology

Simufact Additive is based on MSC´s proven MARC solver technology

  1. Leading solution for non-linear numerical simulations
  2. Covering a broad range of physics
  3. Efficient matrix solvers
  4. Parallelization and speed-up of the analysis by using multiple processor cores and shared memory
  5. Further dedicated advancement for AM purposes
  6. Scalable regarding speed and level of detail
  7. Enables high resolution models with respect to solid fraction
Total distortion of an additively manufactured bracket
Total distortion in an AM built bracket


Software usability

Best-In-Class GUI for Additive Manufacturing process simulation

Process-related icons
Process-related icons

Simufact Additive comes with an intuitive and user-friendly GUI ensuring an extraordinary user experience. The flexible GUI concept allows machine and application-specific dialogs aligned with the real process work flow. A meshing capability is included for the automatic and rapid discretization of even large and complex structures of any shape. The GUI is laid out to smoothly handle these meshes that can readily reach more than a million elements.

Simufact Additive`s best-in-class GUI

  • User-friendly, intuitive use
  • Context sensitive, use right mouse click
  • Prepared for application- and machine-specific dialogs
  • Supports big filigree models
  • Oriented to real AM workflow

Highly realistic results: The comparison of optically measured distortions with simulation-based distortion shows a high correlation.



Automatic generation of support structures

Based on CAD data of the part, Simufact Additive can automatically generate support structures for the manufacturing process.


  • Saves time as no need to continuously go back to the usual support generating software:
    • Different build-positions can be simulated in one tool with their respective support setup
    • Principal studies on support structure positions and properties are possible
    • Build-up orientation can be easily optimized

machine vendor partnerships

Integration of simulation software and 3D printing machines

Simufact is building partnerships with 3D printing machine suppliers aiming at an integrated approach which combines AM simulation software with vendor-specific 3D printers / resp. their build preparation software. The goal is a fully-coupled simulation-based optimization providing the build file for the best configuration. This approach is an important component of our 'right-first-time' strategy.



Integration of simulation software and 3D printing machines

Logo Renishaw

Renishaw plc, a leading manufacturer of advanced metal AM systems, is the first 3D printing machine vendor to collaborate with Simufact in the common goal of an integrated approach. The aim is a fully simulation based optimization leading to the best quality build file. Initially, Renishaw’s QuantAM build preparation software will be coupled with Simufact process simulation software and enable data exchange, using QuantAM’s open API (application programming interface). The next step is to automatically set-up a simulation based on the build information and in return to display the simulation results in Renishaw’s QuantAM build preparation software.


Microstructure simulation

Microstructure simulation for part performance prediction

  1. Draw conclusions for the part´s durability and lifetime
  2. Understand the influence on the part´s final material properties

Efficient use of metallic parts made by additive manufacturing requires the prediction of the part’s performance under various loading condition which is highly sensitive to the inherently heterogeneous location-specific properties of the underlying material. Accurate prediction and control of location specific material properties necessitates accurate knowledge of the underlying microstructure with robust integration with finite element tools.


For the prediction of the microstructures, Simufact will add further functionality to Simufact Additive allowing for transient simulation with linked microstructure. Simufact is collaborating with Materials Resources LLC (MRL), a leader in materials informatics. This collaboration brings to designers and manufacturers the location-specific microstructure effects via an integrated computational microstructure-informed response laboratory (ICMRL) developed by MRL that is used for calibrating and validated Simufact Additive. The insertion of the continuously growing processing, microstructure, and property databases for additively manufactured metals provides Simufact customers with a microstructure-informed modeling tool from powder processing to mechanical performance of a finished part.


Contact Us

Simufact Global Sales & Support Network

Your request will be forwarded to our Global Sales & Support Network that provides best-in-class industry-related application-specific sales and technical services - backed up by qualified local Simufact and Channel Partner experts.

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