Belgian 3D printing company Materialise has launched its simulation software module for metal 3D printing at TCT Show in Birmingham.
The module is being introduced into Materialise Magics software to make simulation easier by optimising production without the need for expert knowledge. Users can apply simulation results directly to support generation and orientation tools in Magics. The module also includes an integrated calibration feature which guides users to the correct simulation settings for their metal machine and can be used in combination with other computer-aided engineering (CAE) solutions for certified metal production.
Materialise says in the typical CAD to print process, the actual printing portion, including machine and material costs, accounts for more than 75 percent of the total cost. As a result, running multiple test prints and printing failed or unsuitable parts can be very costly, particularly for metals where, on average, 15 percent of parts fail. With simulation, operators can predict and analyse the behaviour of a part during physical production by creating a virtual prototype.
“As more companies adopt 3D Printing as an alternative manufacturing technology, service bureaus are operating in a more cost-competitive environment than ever. As a result, they are looking for ways to scale their operations, increase productivity and reduce overall costs”, said Stefaan Motte, Vice President and General Manager of the Materialise software division. “Software, and especially simulation software, will help drive down the primary cost. Our software suite will enable greater access to simulation capabilities and help increase productivity and efficiency.”
The Materialise simulation module for 3D printing is based on an OEM version of the Simufact Additive Solver. Simufact Additive is a powerful and scalable software tool for the simulation of metal-based AM processes. The combination of Simufact’s simulation expertise with Materialise’s data and build preparation software will allow users to better control the pre-build process within their familiar data preparation environment.
Speaking to TCT, Motte says that beta testing of the simulation module both internally and with external partners has shown that build failures can be halved.
“The good thing 3D printing has brought to the making industry is that you can actually expedite the time from concept to produce parts," Motte told TCT. "If you want to bring that to volume you have to go through that optimisation step and if that still takes a long time then you're hindering yourself there and that is where simulation plays such a crucial role. It can make that whole process a lot more cost effective. It can also make that process a lot more time effective by putting it in the virtual world where you can simulate all sorts of different approaches, all sorts of different ideas and select the best out of that and iterate further.”
