Simulation-based Process Preparation For The Additive Manufacturing Of Metal Components

The Amphyon software makes it possible to simulate the AM construction process (AM = Additive Manufacturing) in advance and thus identify and solve possible problem areas of the component to be manufactured before the actual construction process. According to the manufacturer, the software can significantly increase the dimensional accuracy, surface quality, productivity and stability of the AM process. This saves users time and money when developing components for additive manufacturing.

Dr. Nils Keller, CEO of Additive Works: “Despite the high level of technological maturity of additive manufacturing, it can be difficult for inexperienced users in particular to predict whether a component can be manufactured as expected. If a component causes problems, for example with surface defects or severe warpage, this means a waste of machine capacity and material. Our software Amphyon is an answer to this challenge.”He continues:“In the field of conventional manufacturing processes, the use of simulation software is state of the art. With Amphyon, the simulation is now also part of the solution for additive manufacturing. This underlines the growing establishment of industrial 3D printing and the changing requirements for additive series production."

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Virtual process preparation before the actual construction process

Amphyon supports the user in predicting and addressing the potential challenges of a construction job. Numerous, previously experience-based and manually performed process preparation steps are carried out automatically. In this way, companies can optimize their construction contracts in advance of the actual additive manufacturing process, minimize the risk of incorrect construction and benefit from a stable and efficient construction process. In order to enable a clear and simple workflow, the steps of the process preparation are arranged according to the "ASAP" principle (Assessment - Simulation - Adaption - Process), a novel process preparation workflow for direct metal laser sintering (DMLS).

At the assessment level, the Examiner module can be used to carry out a quick geometry analysis and to examine every possible structural orientation of a component. Carrying out this process manually requires, on the one hand, a deep understanding of the process from the user. On the other hand, the application itself has to be taken into account in order to ideally match criteria dependent on the structure orientation, such as the construction time, the required support volume, the reworking effort and the susceptibility to warpage. Using the Amphyon software, the optimal assembly orientation in the installation space of the industrial 3D printer can be calculated for every user with just a few mouse clicks.

Tip: User meeting for lightweight construction At the 3rd user meeting for lightweight construction, which will take place in Würzburg from December 4 to 5, 2018, Dr. Nils Keller will present the Amphyon software and use an example to show how the optimal alignment of the component in the construction chamber can be determined, the process simulation can be carried out and component distortion can be compensated.

More information: User meeting for lightweight construction

In a next step, the simulation will take place on the basis of two further modules: the support module currently in beta and the MPS module (Mechanical Process Simulation). With the support module, optimized support structures can be generated automatically. These connect an additively manufactured component to the construction platform and have a significant influence on the process result. The innovative optimization algorithms of the Amphyon software adapt the support structures themselves and their connection to the component according to the calculated process forces. This not only saves the costs of manual support generation, but also unnecessary support material. In addition, the process stability is significantly increased and faulty structures due to torn support structures can be avoided. The MPS module offers users a fast and intuitive simulation of the assembly process and the calculation of process-induced stresses and component warpage. By creating and building a "preformed" STL file, Amphyon can eliminate these delays. Ultimately, the software enables users to ensure process stability and precise manufacture of the designed component.

To enable a simple and at the same time precise simulation, essential EOS metal materials are available pre-calibrated in the Amphyon software with regard to their material properties. The aim is to calibrate and record all EOS metal materials in the future.

Partnership to optimize industrial 3D printing

“While the general public believes that additive manufacturing enables the creation of a three-dimensional object based on a digital design with just the push of a button, users of the technology know that the reality is more complex. Additive Works and EOS want to make industrial 3D printing together even more user-friendly and intuitive. Therefore, we are very pleased about the close partnership with Additive Works in the area of AM process simulation. The simulation before the actual construction process - 'simulate before you create' - is indeed a key factor in enabling a successful AM construction process with metal materials right from the start,”says Martin Steuer, Head of Product Management Software and Services at EOS.

Amphyon was developed by the start-up Additive Works, founded at the end of 2015, EOS offers its customers this software solution as part of the partnership. In addition, the two companies are driving Amphon's further development together. The aim is to integrate the Ampyhon functionalities for orientation, simulation and support generation into the EOSprint 2 data preparation and process management software from EOS.