Next level precision: introducing Simufact Additive PBF process and defect analysis

A novel multi-scale process simulation approach for location-specific defect predictions within full-scale geometries

four types of exposure maps

Predict thermal history and defect formation for metal AM

Simufact introduces a revolutionary module that takes Metal Laser Powder Bed Fusion (L-PBF) process simulation to the next level. Predict defects, optimize processes, and empower engineers with unprecedented accuracy.

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Key highlights

  • Precision at Every Level: Simufact Additive Defect Prediction Solution introduces a groundbreaking multi-scale simulation, swiftly predicting defects at individual scan vectors and powder layers for unparalleled precision.
  • Efficiency Redefined: Experience rapid thermal history and defect predictions, coupled with local parameter optimization, empowering engineers to streamline processes and make informed decisions efficiently.

Unlock unparalleled precision in Metal Laser Powder Bed Fusion (L-PBF) with Simufact's latest innovation – the PBF Process and Defect Analysis solution (PDA). Approximately one year before its release, Hexagon and Raytheon Technologies partnered to deliver a simulation tool that enables evaluation and optimization of metal additive manufacturing (AM) processes through the prediction of thermal history and defects at the laser path and powder layer scale. Through a powerful combination of Simufact Additive’s and Raytheon Technologies’ Pratt and Whitney business, the new feature helps designers and engineers evaluate the print outcome and test combinations of materials, geometries, and print processes without expensive and time-consuming physical test runs.

Addressing existing challenges in Additive Manufacturing, our solution enables engineers to both predict thermal history and defects swiftly, at the individual scan vector and powder layer level - and anticipate and mitigate risks associated with local defects, such as keyholing, lack of fusion, balling up, and surface roughness.

What sets this feature apart is its ability to determine the process parameter window locally, for any part location, while considering the local geometry and temperature of the substrate before laser application. This is achieved through a combined analytical-numerical approach on the part scale, incorporating material properties, operational conditions, and part geometry.

Jeff Robertson, Hexagon’s director of global business development points out which main challenge is tackled by PDA: “The ability to evaluate full laser powder bed fusion (L-PBF) parts on the meso-scale will reduce the effort to achieve part certification and thereby support industrialisation of metal 3D printing.”

single stripe and single track maps

PBF Process and Defect Analysis can be incorporated before Simufact Additive’s Metal Powder Bed Fusion (MPBF) process simulation, in order to identify the best process settings to achieve a defect free part. Subsequently, Simufact Additive’s detailed simulation of the MPBF process based on the identified settings can be used to calculate part distortions after both build and post build stages. One can then compensate the distortions on the part and export the compensated part for the physical production.

This most-effective solution empowers engineers to evaluate build processes, assess the risk of defects based on proposed parameters, and to make informed modifications to mitigate risks. Stay ahead in Additive Manufacturing with Simufact's Additive Defect Prediction Solution – precision, efficiency, and innovation in every layer.


About Simufact Additive

Simufact Additive is a scalable software solution for the simulation of metal-based additive manufacturing (AM) processes which focuses on laser powder bed fusion (L-PBF), and metal binder jetting (MBJ) processes.

It is a software solution designed to predict and compensate for distortion, compute residual stress and temperature distribution throughout the printing, heat treatment, cutting, hot isostatic pressing (HIP) as well as machining processes virtually, before the physical, tangible part is manufactured by the 3D metal printer.

Ultimately, Simufact Additive allows the user to overcome the AM obstacles and to print AM parts right the first time.