Metal Binder Jetting: Finite Element Simulation-Based Design
FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization
Metal Binder Jetting (MBJ) is an emerging additive manufacturing technology that has several key advantages over common Powder Bed Fusion processes; high volumes of parts can be printed with minimal spacing; no support structures are needed, and larger lot sizes are possible. It has the potential to replace low-volume, high-cost metal injection moulding for everything from automotive and aircraft parts to medical applications. Because high resolution is possible, it could also reduce the cost and lead times for production of complex and lightweight metallic parts such as gears or turbine wheels.
Metal AM (Additive Manufacturing) FEA Simulation and Optimization
Our Finite Element-Based solution for Metal Additive Manufacturing, puts its focus on build simulation and subsequent steps including heat treatment, cutting the base plate, removing supports, and Hot Isostatic Pressing (HIP). The process simulation solution addresses both manufacturers and researchers and their needs.
- Shorten your training process dramatically
- Investigate more variable prior to the production
- Shorten time-to-market
- Reduce material and energy consumption costs
Our solution’s functionality helps you to answer challenges in Metal AM (Additive Manufacturing) Finite Element Simulation-based design and Optimization:
- Identify the best build orientation
- Determine and compensate final part distortionGenerate and optimize support structures
- Process window pre-scanning tool
- Powder coating
- Melt pool shape and dimensions
- Consolidated material porosity
- Surface roughness
- Thermal history as a function of deposition strategy
- Residual stresses
- Distortion during build process and after release
- Identify manufacturing issues such as cracks, layer offsets, recoater contact
- Predict the influence of several components in the build space
- Identify cold and hot spots due to thermal/thermo-mechanical simulation
- Examine conditions of highly elevated temperatures and pressures – HIP proces
Optimizing the design parameters for additive manufacturing
FEA Based Simulation enable our engineering team to gain insight into the microscale meltpool phenomena by performing full factorial studies with various process parameters for determine the best process parameters for any machine/material combination, and ensures the achievement of the highest integrity parts, as well as the expected microstructure and physical properties:
- Optimize and fine-tune their machine and material parameters.
- Develop new metal powders and metal AM (Additive Manufacturing ) materials and material specifications.
- Determine optimum machine/material parameters.
- Control microstructure and material properties.
- Manufacture using new metal powders faster and more efficiently.
- Reduce the number of experiments needed to qualify components.
- Mitigate risk while accelerating innovation.
- Analyze Porosity and Meltpools.
- Thermal history and microstructure information.
- Determines the percentage of porosity in a part due to lack of fusion.