Additive Works is known for its Amphyon software, a simulation tool that goes through the process of an additive manufacturing build before it actually takes place, highlighting and optimizing possible problem areas. The goal of the software is to find and address all possible issues before the 3D printer is even fired up, eliminating bad builds and enabling the user to get a flawless print on the first try. Amphyon is the focus of a new collaboration between Additive Works and metal 3D printer manufacturer EOS.

“Although the AM-technology itself is very mature, especially for unexperienced users it can be difficult to predict if a part will be 3D printed as expected,” said Dr. Nils Keller, CEO of Additive Works. “So when a part is manufactured with issues, e.g. surface defects, it means a waste of machine time and material costs. An answer to this challenge is Amphyon. Using simulation software is standard when it comes to conventional manufacturing methods. With Amphyon, simulation now also becomes a solution for additive manufacturing, underlining the increased use and changing requirements of industrial 3D printing for serial production.”

Amphyon software is easy to use, structured along the company’s “ASAP” principle: Assessment, Simulation, Adaption, and Process. The software has a couple of different modules and focuses on part assessment, support optimization and process simulation. In the Assessment stage, an examiner module evaluates the part geometry, assesses all possible build orientations, and automatically finds the best one.

Two modules are available in the Simulation stage: the Support module, currently in beta, and the Mechanical Process Simulation (MPS) module. In the Support module, optimized support structures are generated automatically. The module’s optimization routines adapt the support perforation as well as the interfaces between part and support based on the calculated process loads. The time and cost of manual support generation is eliminated, support material is saved, and process stability is increased, avoiding expensive build fails. The MPS module presents a fast, easy way to simulate process mechanics and calculate and compensate for distortions.

Under the new partnership, certain EOS metal materials are being integrated into Amphyon software and calibrated with regard to their material properties. Eventually, all metal materials from EOS will be calibrated and implemented into the software.

“While the vast majority of the public thinks that additive manufacturing allows for the creation of three dimensional objects from a digital design by just clicking a button, users of the technology know that the reality is more complex,” said Martin Steuer, Head of Product Management Software and Services at EOS. “United by the mission to make Industrial 3D printing even more intuitive and user friendly, EOS is happy to partner with Additive Works on the subject of AM-process-simulation. ‘Simulate before you create’ really is a key factor to ensure a successful laser sintering process with metal materials, right from the start.”

EOS will also be offering the Amphyon software to its customers as part of the partnership. Both companies will develop further enhancements for the software, and the Amphyon assessment, support and simulation modules will be integrated into EOSPRINT 2, EOS’ job and process management software.

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