Additive Manufacturing Simulation

America Makes and Air Force Research Laboratory Challenge Series: Winner Macro-scale Process-to-Structure Predictions

• AFRL AM Challenge Series Improved Understanding of the Internal Structure and Resultant Performance of Metallic Components Produced by AM | America Makes (July 20, 2020)

NIST AM-BENCH Test Series: Best Results Predicting Residual Stresses

• AM-Bench 2018 Benchmark Challenge Submissions and Awards | NIST (June 20, 2018)

Full thermal-mechanical simulation methods for accurate distortion and stress prediction, including buckling

• Effective residual stress prediction validated with neutron diffraction method for metal large-scale additive manufacturing | Materials and Design -Journal- Elsevier (July 2021)

The full thermal-mechanical solution provides a detailed thermal response that can be used to predict microstructure properties including melt pool, unfused powder, phase transformation, grain morphology, and mechanical properties

• Estimates of the mechanical properties of laser powder bed fusion Ti-6Al-4V parts using finite element models | Materials and Design -Journal- Elsevier
• A metallurgical phase transformation framework applied to SLM additive manufacturing process | Materials and Design -Journal- Elsevier

Advanced solver capabilities

• Reduced order modeling via PGD for highly transient thermal evolutions in additive manufacturing | Computational Methods in Applied Mechanics and Engineering

PARTNERSHIPS

• Join the DELMIA Fabrication Community to learn how to connect additive manufacturing printers to the 3DEXPERIENCE platform
• Learn how Renishaw and Dassault Systemes work together to deliver a no-compromise end-to-end AM design experience

NEWS

• Dassault Systèmes in Additive Manufacturing | additivemanufacturing.com
• RIZE and Dassault Systèmes partner to enhance additive manufacturing user experience | tctmagazine.com (December 10, 2019)
• Science in the Age of Experience: Additive Manufacturing Symposium Draws Expert Discussion on Progress, Challenges | 3DPrint.com (Jun. 20, 2018)
• Aerospace, Architecture, Consumer Applications Highlight 3D Printing Usage in Additive Manufacturing Symposium | 3DPrint.com (Jun. 21, 2018)
• Expert Discussion Looks to the Future of 3D Printing, Supply Chain, Democratization | 3DPrint.com (Jun. 21, 2018)
• Workforce is Key to the Development of Additive Manufacturing: Interview with Women in Manufacturing | 3DPrint.com (Jun. 20, 2018)
• Bursting Additive Manufacturing’s Last Bubbles | Rapid Ready Tech (Jun. 20, 2018)
• Mainstreaming of Additive Manufacturing: An Ecosystem Perspective | 3DPrint.com (Jun. 22, 2018)

The 3DEXPERIENCE platform integrates design, simulation, and production workflows, enabling seamless collaboration and data management. It helps optimize processes, improve accuracy, and accelerate product development cycles.

Many industries benefit from SIMULIA's additive manufacturing capabilities, including aerospace, automotive, and medical sectors. These industries require high-performance components with intricate designs that traditional manufacturing methods cannot achieve. By utilizing SIMULIA's tools, companies can innovate faster and significantly improve their product offerings.

Yes, SIMULIA supports multi-material additive manufacturing by allowing simulations that account for different material properties and interactions. This capability enables designers to create more sophisticated parts that harness the strengths of various materials, optimizing performance and functionality.

SIMULIA is a useful tool for additive manufacturing. It offers simulations that optimize designs by analyzing material behavior and thermal effects. This can enhance part quality and streamline workflows with other Dassault Systèmes tools.

Through advanced simulations, SIMULIA tackles common challenges in additive manufacturing, such as thermal distortion and material weaknesses. By modeling the additive process, users can gain insights into potential defects and make necessary adjustments during the design phase. This proactive approach minimizes errors and wasted materials, ultimately leading to cost savings and improved product quality.

• Vat Photopolymerization – Uses liquid resin cured by light (e.g., SLA - Stereolithography, DLP - Digital Light Processing)—example: High-detail prototypes in automotive and medical industries.
• Material Jetting Deposits droplets of material layer by layer (e.g., PolyJet, NanoParticle Jetting). An example is full-color, multi-material prototypes for product design.
• Binder Jetting – Binds powder materials using a liquid agent (e.g., sand, metal, or ceramic printing)—examples: Metal casting molds, sand cores, and architectural models.
• Powder Bed Fusion (PBF) – Uses a laser or electron beam to fuse powder particles (e.g., SLS - Selective Laser Sintering, DMLS - Direct Metal Laser Sintering, EBM - Electron Beam Melting). Example: Aerospace and medical implants due to high strength and precision.
• Directed Energy Deposition (DED) uses a focused energy source (laser, electron beam, or plasma) to melt material as it is deposited. Examples include repairing and building large metal parts in aerospace and defense.
• Material Extrusion Deposits material through a nozzle (e.g., FDM—Fused Deposition Modeling). Examples include consumer 3D printing, jigs, and fixtures in manufacturing.
• Sheet Lamination Bonds thin sheets of material layer by layer (e.g., UAM—Ultrasonic Additive Manufacturing, LOM—Laminated Object Manufacturing). Examples include low-cost prototyping and hybrid manufacturing for metal components.