Simufact Additive 3 comes with new functionality, such as the thermo-mechanical calculation method, consideration of baseplate-related effects on the printing process, or the simultaneous simulation of several components in the build space.
‘Today companies employing AM technology for printing metal parts have to cope with failure in their production processes and the high knock on costs associated with this. Simufact Additive is an important tool which will help these companies get it ‘right first time’, by regularly running simulations prior to production.’
Michael Wohlmuth, CEO Simufact
‘For the technical heart of the software we developed an application-specific solver based on MSC’s powerful generic Marc solver. Simufact Additive will be able to capture the complete process chain in the manufacturing environment and to scale the simulation based on the user requirements. The key driver is accuracy followed by speed. Therefore, we have developed a completely new infrastructure specially dedicated to AM.’
Dr. Hendrik Schafstall, CTO Simufact
Insight into Simufact Additive
Highlight of Simufact Additive 3 is the thermo-mechanical calculation method. Learn more.
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.
MSC's latest Simulating Reality magazine is a pure Additive Manufacturing issue – introducing new simulation solutions for Metal and Plastics additive manufacturing, showcasing real examples and providing insights into what´s coming next in AM simulation – from MSC´s e-Xstream and Simufact.
Simufact Additive is a powerful and scalable software solution for the simulation of metal-based additive manufacturing processes.
Simufact Additive helps you produce AM parts first-time-right:
Replace time-consuming testing with simulation methods!
Employ Simufact Additive process simulation and save time and money:
... Simufact Additive will lead the way.
Simufact Additive covers the simulation of Powder Bed Fusion processes, e.g. known as:
Please note that the simulation of Laser Deposition Methods (LDM) is covered by Simufact Welding.
Covering the complete AM process chain (in combination with MSC products)
Simufact Additive covers the core manufacturing process chain including
Read more about MSC´s complete AM solution portfolio:
Simulation of distortion of an additively manufactured manifold
Simulation of effective stress of an additively manufactured aerospace bracket
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.
With friendly permission by NDES.
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:
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.
Simufact Additive is based on MSC´s proven MARC solver technology
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:
Highly realistic results: The comparison of optically measured distortions with simulation-based distortion shows a high correlation.
Based on CAD data of the part, Simufact Additive can automatically generate support structures for the manufacturing process.
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.
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.
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.
- Cracks located at the interface between the par/base plate and the part/support
- Undesired distortion
- Failure analysis by simulation
- Distortion compensation by adding inserts and new supports structure
Re-construction of a conventional hinge hood aiming at substantial weight reduction, fewer component arts, less assembly steps, and integrated pedestrian protection functionality - to be manufactured using metal additive manufacturing methods.
In order to reduce the number of try-out steps, Simufact simulated the distortions in the AM parts. By distortion compensation countermeasures the parts were produced in shorter time meeting quality goals.
Visit the LightHinge+ website in order to learn more about the project.
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