3D Printing Thermal Deformation Prediction
Solved with automatic model correction function

On November 30th, Siemens PLM Software announced a new Additive Manufacturing (AM) process simulation solution capable of predicting distortion that can occur during 3D printing. This product is fully integrated with Siemens' end-to-end additive manufacturing solution, enabling manufacturers to leverage it for part design and printing at scale.
The new AM process simulation solution builds on Siemens' comprehensive digital innovation platform and Simcenter portfolio. Using a digital twin, it simulates the build process before printing, predicting potential distortion during the printing process, and automatically generates corrected geometry to compensate for the distortion. These simulation processes are not only critical to achieving “first time right” designs, but also to achieving the efficiency gains essential for fully industrializing the additive manufacturing process.

“We at toolcraft have successfully completed our additive manufacturing process using the Simcenter 3D AM Process Simulation solution,” said Christoph Hauck, CEO of MBFZ toolcraft. “Our real-world tests have given us confidence that Siemens’ AM Process Simulation solution can significantly enhance the quality of the output from our print process.”

Typically, when 3D printing metal parts, the method used to fuse the print layers involves heat generation. As the layers build up, residual heat can cause thermal deformation of the parts within the printer. This can lead to various problems, including structural issues within the part and print interruptions. These issues often lead to print failures and make it extremely difficult to achieve a "right first time" print. However, Siemens' printing process simulation can significantly alleviate these issues.

Siemens' new process simulation product is integrated into the Powder Bed Fusion Process (PBF) process within Siemens PLM Software's additive manufacturing portfolio and is used to predict distortion during metal printing. Users can use the provided manufacturing sequence to assess thermal distortion, predict recoater collisions, and predict overheating areas. Important feedback on the printing process is also provided.

Furthermore, the AM process simulation solution provides the ability to iterate solutions across the design and build tray setup stages of the manufacturing sequence, as well as the simulation stage. This closed feedback loop is made possible by integration with the Siemens Digital Innovation Platform. Simulation data informs the step-by-step printing process, ensuring a seamless digital information thread. This digital backbone enables the system to develop pre-compensated models. More importantly, design modifications and machining processes can all be seamlessly implemented within NX, without additional data conversion. This high level of integration is what customers need today to successfully implement industrialized additive manufacturing.

“This solution is the latest addition to our integrated additive manufacturing platform, which empowers customers to industrialize additive manufacturing by designing and printing useful parts at scale,” said Jan Leuridan, senior vice president, Simulation and Test Solutions, Siemens PLM Software. “By integrating empirical and analytical methods, we have increased the accuracy of the simulation process, creating a digital twin and helping customers better predict real-world print outcomes.”

“We’ve validated this over several months through real-world testing with our own select first-party adopters, providing them with refined geometries and closed-loop feedback to help them achieve better results in their additive manufacturing process,” he added. “This empowers our customers to achieve right-first-time printing and drive innovation.”

The AM Process Simulation solution is scheduled for release in January 2019 as part of the latest NX software and Simcenter 3D software.