Process Simulation for
Additive Manufacturing
1 © 2017 ANSYS, Inc. September 29, 2017
Additive Manufacturing Introduction
Additive manufacturing (or 3D printing) builds 3D objects by
adding a layer-upon-layer of material
− Plastics (polymers)
− Metals Our Focus
− Other materials (including biological) Laser Scanner
Roller
Object being
fabricated
Powder
Delivery
system
Fabrication powder bed
Powder delivery piston Fabrication piston
Fused Deposition Modeling (FDM) Powder Bed Fusion (PBF)
2 © 2017 ANSYS, Inc. September 29, 2017
Metal Process Categories of Interest
• Powder Bed Fusion (PBF) also known as
− Direct metal laser sintering (DMLS) or Direct metal laser
melting (DMLM)
− Electron beam melting (EBM)
− Selective laser melting (SLM)
• PBF processes use either a laser or electron beam to
melt and fuse metal powder together that is laid
down one layer at a time
3 © 2017 ANSYS, Inc. September 29, 2017
Metal Process Categories of Interest
• Directed Energy Deposition (DED) also known as
− Laser engineered net shaping (LENS)
− Direct metal deposition
− 3D laser cladding
• DED processes introduce powder or a wire into the
path of a laser or electron beam, melting and
depositing it onto the solidified material below
4 © 2017 ANSYS, Inc. September 29, 2017
Challenges in Additive Manufacturing
It can take multiple build tries until a successful build
is obtained
− Recoater arm interference (blade crash)
− Breaking off from supports
− Part fracture
− Excessive distortion
−…
Need Process Simulation to
Get it Right the First Time!
5 © 2017 ANSYS, Inc. September 29, 2017
Process Simulation Requirements
• Tool focusing on the current Mechanical user
− In the design/analysis loop
− Not the process engineer/technician setting the machine process
parameters
• User does not know details of the AM process or machine…
but will need to know basic build parameters
• Mimic the process
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6 © 2017 ANSYS, Inc. September 29, 2017
Process Simulation Goals
Answer the questions about the design
• Is this buildable?
• What is the thermal distortion?
• How do I compensate in the design for
the distortion?
• What is the best build orientation?
• What are the best supports to use, and
where?
Provide Design Guidance
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7 © 2017 ANSYS, Inc. September 29, 2017
Simulation Overview
• Model evolves over time
− Using standard ANSYS element birth techniques
− BCs updated internally as the build progresses
• Time itself is an internal variable
− Based on current layer size and process parameters
− Not user controllable
8 © 2017 ANSYS, Inc. September 29, 2017
Workbench View
Design Process Simulation
End-to-End Workflow
Parametric
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Process Simulation Example
Geometry Mesh
Box Support
“Hollow Airfoil”
America Makes Project #4026
Development of Distortion Prediction
& Compensation Methods for Metal
Powder-Bed AM
10 © 2017 ANSYS, Inc. September 29, 2017
Process Simulation Example
Transient thermal simulation of layers being built Static structural showing build-up of deformation
11 © 2017 ANSYS, Inc. September 29, 2017
Validation: Canonical Test Case
America Makes Project #4026
Development of Distortion
Prediction & Compensation
Methods for Metal Powder-Bed
AM
12 © 2017 ANSYS, Inc. September 29, 2017
Results Comparison
3DSIM Autodesk Netfabb ANSYS
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Statistics
116K nodes
92K elements
276 solution time points
10 CPU solver used
9 m thermal solve time
1 h structural solve time
14 © 2017 ANSYS, Inc. September 29, 2017
Current Status
• Available at 18.2 (current release) as beta
− No license required
• Fixes and enhancements at 19.0 (Jan 2018)
− Still beta (need more feedback and continued validation)
− License will be required (no charge)
• 19.x release
− Part of additive product bundle
− Licensed with upcharge TBD
15 © 2017 ANSYS, Inc. September 29, 2017