It adds the capability of full part Thermal Strain predictions to Assumed Uniform and Scan Pattern strain. This allows engineers to use detailed additive manufacturing science in order to:
- accurately predict part dimensions
- automatically correct for distortion and optimize supports
- visualize the effects of part orientation, process parameters and machine differences on 3D printed parts
“Seven years ago, as academics, Deepankar Pal (3DSIM’s Chief Scientist) and I decided to address the trial-and-error experimentation inherent in AM. We set out to build a suite of solvers to analyze laser/material interactions and material transformations fast enough to enable prediction for how different geometries, laser scan strategies, process parameters, and powder properties affect the accuracy and microstructure of full-scale AM-produced metal parts. Many people told us our dream for predicting full-part characteristics at meltpool-scale accuracy was impossible,” said Dr. Brent Stucker, CEO, 3DSIM. “Today we’re pleased to say that not only is it possible, it’s accessible world-wide using any internet-connected computer, smart phone and tablet. I’m excited that we’ve achieved our technical goals, building the most capable AM simulation tool in the world – exaSIM ULTIMATE. I’m looking forward to working with our customers to see how they leverage exaSIM to break down barriers to metal AM implementation and production.”
The company is focused on creating software tools that allow for predictions, based in physics, of additive manufacturing process outcomes before a part is built. The exaSIM suite offers important insight into the complexities of laser powder bed fusion, and comes up with solutions to issues like distortion, residual stress, and build failure, so users can achieve part tolerance without having to go through lengthy trial and error processes.
By being proactive and embedding exaSIM ULTIMATE into a front-end production workflow, users can enhance quality, and reduce postmortem analysis and rebuilding of non-conforming parts later. The software automatically generates two types of support structures, based on residual stress predictions, so users won’t waste material and time by adding supports where they don’t need to be. exaSIM will automatically compensate for STL file distortion during production, and helps prevent build failure with its Blade Crash detection feature. The software also helps with development and training of advanced design for AM (DFAM) skills, as it offers a “deeper insight into design and production dynamics.”
“The message we continually hear from users of exaSIM is how it has dramatically impacted their first-time- build success rate. One of our early adopters, who is highly experienced and skilled with metal AM, has reported a 70% improvement from before using our predictive tools. His operation now sustains over a 90% first-time success rate with the implementation of part simulation using exaSIM as a standard practice in their workflow,” said Ron Clemons, Director of Business Development, 3DSIM. “With 20 years’ experience in additive manufacturing myself, I can confidently say the exaSIM predictive and compensative tools are vital for moving laser powder bed fusion beyond the limits of niche manufacturing to serial production across a broad array of industries and applications.”
exaSIM ULTIMATE will increase innovation, and reduce build concerns, at companies, helping machine operators and designers successfully optimize design and build strategies. It also runs in a secure cloud environment, to enable data storage, higher speed, ease of use, and fast feature implementation; a GovCloud option is available for companies with ITAR restrictions.
You can purchase exaSIM ULTIMATE for $2,000, billed on a monthly basis, though the first two months are free with a prepaid annual subscription. You can also sign up for a free 30-day trial.
Discuss this and other 3D printing topics at 3DPrintBoard.com, or share your thoughts in the Facebook comments below.