Additive Manufacturing

Simulate your additive processes; Easy-to-Use GUI

Reduce Distortion and Scrap

3D printing of metal components offers companies a way to rapidly create near net-shape components without costs and lead-time involved in the creation of complex tooling.

The nature of the manufacturing process also allows the production of components that might be impossible to make by any other means offering the designer lighter weight options.

A relatively new technology

The nature of the manufacturing process also allows the production of components that might be impossible to make by any other means offering the designer lighter weight options.

As a relatively new technology, there can be a lot of trial and error in the set-up process laying out the orientation and support structures for printing a part and the high-temperature nature of the selective melting process can result in parts with residual stresses and distortion.

Each failed run costs money and time, so having a way to simulate the process steps of printing a part, heat treating it, removing the support structure and hot isostatic pressing to consolidate it would have benefits both technical and commercial to companies using this technology.

At Desktop Engineering we can deliver a software tool, based on a state-of-the-art FEA solver, with an easy to learn process-oriented interface (GUI) that can be used to improve your 3D metal printing process.

This solution is appropriate to all powder bed fusion type processes.

Benefits

Technical Benefits

  • Calculate deformation of final part to reduce distortion and improve tolerances
  • Minimise residual stress to improve strength and fatigue life
  • Find best build-up orientation
  • Develop right support structure
  • Model post-build processes – heat treatment, support removal and porosity reduction with HIP process

Commercial Benefits

  • Reduce learning process and associated costs dramatically
  • Run more variations digitally prior to production to reduce costs
  • Reduced time-to-market
  • Increase machine/manpower availability and productivity
  • Reduce material and energy consumption costs
  • Reduce scrap and aborted runs

Ease of use

While this technology is based on one of the most powerful FEA systems on the market, you do not need to be an FEA specialist in order to use this tool.  A workflow-based environment leads you through defining the orientation and support structure, and the post-production processes.

Manufacturing Challenges

Our software partners have presented an interesting review of the status of 3D Additive Manufacturing in industrial processes, including a discussion on simulation of these process and what benefits this can bring.

Simufact.Welding

Simufact.welding realistically predicts distortions and residual stresses; helps user determine appropriate strategies to minimize them. Reach your aim more quickly with process specific functions.

Simufact videos

Insight

#BeyondBIM2021 Symposium Highlights

Key TakeAways 

Desktop Engineering has concluded its annual BeyondBIM virtual event with a broad consensus that in the future the construction industry needs to grasp new technologies to drive improved processes, together with recognising the need to train in these new methods.

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Company Restructuring & Software Licencing

Since the start of the COVID-19 crisis companies in the aerospace design and manufacturing sector have been particularly affected by the economic impact of the disruption to worldwide economies. Some have seen their orders and revenues drop immediately by sometimes 50% driven by the reduction in production of new aircraft.  

These companies have had to quickly reduce costs and take advantage of any state support.

However, those with low cash reserves have seen the need to restructure through some form of merger, sale or even some type of insolvency process.

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“We wouldn’t have got our first car to the grid without Desktop Engineering’s help.”

F1 Team Principal