Finite Element Simulation of Powder Bed Fusion Processes

FEA & CFD Based Simulation Design Analysis Virtual prototyping MultiObjective Optimization

Powder Bed Fusion (PBF) technique enables the manufacturing of a vast array of geometrically complex products using a heat source, mainly laser or electron beams, to fuse powder particles layer-by-layer, therefore forming a solid part. Manufacturers can benefit from substantial freedom of design considering that PBF presents several viable technologies and materials.

Laser Beam Melting LBM principle with machine scheme additive manufacturing am Finite Element simulation Simufact abaqus ansys MSC Marc Digimat 32

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

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) uses lasers to sinter, or coalesce, powdered material layer-by-layer to create a solid structure. The main materials used in the SLS 3D printing process include polyamide, Alumide, and rubber-like materials. Nylons are strong and durable but do feature some flexibility, making them excellent for snap fits, brackets, clips, and spring features. Designers should take the susceptibility for shrinkage and warping of thin parts into consideration during the conceptual phase.  

Selective Laser Melting (SLM)

The same technical principle is used to produce Selective Laser Melting (SLM) parts, but is exclusively used to produce metal parts. SLM achieves a full melt of the powder so that single-component metals, such as aluminum, can be used to create light, strong spare parts and prototypes. DMLS sinters the powders and is restricted to alloys, including titanium-based alloys. These methods require added support to compensate for the high residual stress and to limit the occurrence of distortion.

Electron Beam Melting (EBM)

Electron Beam Melting technology attains fusion with the use of a high-energy electron beam and produces less residual stress resulting in less distortion. It uses less energy and can produce layers faster than SLS. This method is most useful in high-value industries such as aerospace and defense, motor sports, and medical prosthetics.

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
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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.
additive manufacturing am Finite Element simulation Simufact abaqus ansys MSC Marc Digimat


We pride ourselves on empowering each client to overcome the challenges of their most demanding projects.

Enteknograte offers a Virtual Engineering approach with FEA tools such as MSC Softwrae(Simufact, Digimat, Nastran, MSC APEX, Actran Acoustic solver), ABAQUS, Ansys, and LS-Dyna, encompassing the accurate prediction of in-service loads, the performance evaluation, and the integrity assessment including the influence of manufacturing the components.
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