Altair Case Studies Automating Support Generation for Laser Beam Melting with Additive Works’ Amphyon

	Automating Support Generation for Laser Beam Melting with Additive Works’ Amphyon Altair

Automating Support Generation for Laser Beam Melting with Additive Works’ Amphyon

Altair

Technology Category	Analytics & Modeling - Digital Twin / Simulation Sensors - Lidar & Lazer Scanners
Applicable Industries	Aerospace Education
Applicable Functions	Product Research & Development Quality Assurance
Use Cases	Manufacturing Process Simulation Virtual Reality
Challenge	Laser Beam Melting (LBM) technology allows for the creation of complex metallic parts without material waste, finding applications in industries such as aerospace. However, the process is essentially a micro welding process, and thermo-mechanical phenomena play a significant role. The heat from the melting material must dissipate, and the force from the contraction of the weld paths must be compensated. To maintain temperature and keep the part attached to the build plate, additional support geometries are added to the part. This not only increases material usage but also necessitates additional post-processing. The process stability is heavily dependent on the support structure. If the supports are not strong enough or do not conduct heat effectively, the quality and shape of the part can deviate from the desired result. Cracking of supports during the process can lead to process abortion, potentially doubling the costs per part, especially for parts being printed for the first time. Read More
About Customer	The customer in this case is any industry or organization that utilizes Laser Beam Melting (LBM) technology for the creation of complex metallic parts. This includes, but is not limited to, the aerospace industry. These customers often face challenges with the LBM process, particularly in terms of the thermo-mechanical phenomena that occur during the process. The heat from the melting material must be dissipated, and the force from the contraction of the weld paths must be compensated. This often requires the addition of support geometries to the part, which increases material usage and necessitates additional post-processing. The stability of the process is heavily dependent on these support structures, and if they are not sufficient, the quality and shape of the part can deviate from the desired result. Read More
Solution	Additive Works aims to replace the extensive iterations involved in support generation with process simulation and optimization. The upcoming support module of the Amphyon software ensures that critical values are not exceeded and automatically creates the support geometry accordingly. The applied routine optimizes spatially varied parameters for thin-walled support structures, allowing for dense support walls in critical regions with high mechanical loads and coarse walls with large perforations where powder removability is more important. After the optimal support parameters have been calculated, the software can automatically generate corresponding support structures, including interfaces between part and support that are dimensioned to ensure a stable process and minimized post-processing effort. The software also allows for the automatic generation of support structures for first-time-right LBM, saving material and reducing the required build time. This simulation-driven workflow requires significantly less user interaction, decreasing process development costs of critical parts and introducing a new state-of-the-art in automation of support generation in LBM. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Digital Twin / Simulation

Sensors - Lidar & Lazer Scanners

Applicable Industries

Aerospace

Education

Applicable Functions

Product Research & Development

Quality Assurance

Use Cases

Manufacturing Process Simulation

Virtual Reality

Challenge

Laser Beam Melting (LBM) technology allows for the creation of complex metallic parts without material waste, finding applications in industries such as aerospace. However, the process is essentially a micro welding process, and thermo-mechanical phenomena play a significant role. The heat from the melting material must dissipate, and the force from the contraction of the weld paths must be compensated. To maintain temperature and keep the part attached to the build plate, additional support geometries are added to the part. This not only increases material usage but also necessitates additional post-processing. The process stability is heavily dependent on the support structure. If the supports are not strong enough or do not conduct heat effectively, the quality and shape of the part can deviate from the desired result. Cracking of supports during the process can lead to process abortion, potentially doubling the costs per part, especially for parts being printed for the first time.

About Customer

The customer in this case is any industry or organization that utilizes Laser Beam Melting (LBM) technology for the creation of complex metallic parts. This includes, but is not limited to, the aerospace industry. These customers often face challenges with the LBM process, particularly in terms of the thermo-mechanical phenomena that occur during the process. The heat from the melting material must be dissipated, and the force from the contraction of the weld paths must be compensated. This often requires the addition of support geometries to the part, which increases material usage and necessitates additional post-processing. The stability of the process is heavily dependent on these support structures, and if they are not sufficient, the quality and shape of the part can deviate from the desired result.

Solution

Additive Works aims to replace the extensive iterations involved in support generation with process simulation and optimization. The upcoming support module of the Amphyon software ensures that critical values are not exceeded and automatically creates the support geometry accordingly. The applied routine optimizes spatially varied parameters for thin-walled support structures, allowing for dense support walls in critical regions with high mechanical loads and coarse walls with large perforations where powder removability is more important. After the optimal support parameters have been calculated, the software can automatically generate corresponding support structures, including interfaces between part and support that are dimensioned to ensure a stable process and minimized post-processing effort. The software also allows for the automatic generation of support structures for first-time-right LBM, saving material and reducing the required build time. This simulation-driven workflow requires significantly less user interaction, decreasing process development costs of critical parts and introducing a new state-of-the-art in automation of support generation in LBM.

Impact #1	The implementation of Additive Works' Amphyon software has revolutionized the Laser Beam Melting (LBM) process. By replacing the extensive iterations involved in support generation with process simulation and optimization, the software has made the process more efficient and cost-effective. The software ensures that critical values are not exceeded and automatically creates the support geometry accordingly. This has resulted in more stable and reliable LBM processes, with the quality and shape of the parts being more consistent with the desired result. Furthermore, the software has reduced the need for user interaction, making the process more user-friendly and less time-consuming. This has taken the LBM technology a significant step further, introducing a new state-of-the-art in automation of support generation.

Impact #1

The implementation of Additive Works' Amphyon software has revolutionized the Laser Beam Melting (LBM) process. By replacing the extensive iterations involved in support generation with process simulation and optimization, the software has made the process more efficient and cost-effective. The software ensures that critical values are not exceeded and automatically creates the support geometry accordingly. This has resulted in more stable and reliable LBM processes, with the quality and shape of the parts being more consistent with the desired result. Furthermore, the software has reduced the need for user interaction, making the process more user-friendly and less time-consuming. This has taken the LBM technology a significant step further, introducing a new state-of-the-art in automation of support generation.

Benefit #1	Material use was decreased by 28.8%.
Benefit #2	The process development costs of critical parts were significantly reduced.
Benefit #3	The required build time was also reduced due to the saving of material.

Benefit #1

Material use was decreased by 28.8%.

Benefit #2

The process development costs of critical parts were significantly reduced.

Benefit #3

The required build time was also reduced due to the saving of material.

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Overview

Automating Support Generation for Laser Beam Melting with Additive Works’ Amphyon

Operational Impact

Quantitative Benefit