Simulation tool for metal 3D printing ‘will predict defects before they happen’

A new simulation tool will predict defects in additively-manufactured metal parts before they have happened, two companies have claimed.

Combining technologies from Hexagon’s Manufacturing Intelligence division in Milton Keynes and Raytheon Technologies’ US aerospace manufacturer Pratt and Whitney, the new software is aimed at enabling evaluation and optimisation of metal additive manufacturing (AM) processes through the prediction of thermal history, and defects at the laser path and powder layer scale.

Analysis will help designers and engineers evaluate the print outcome and test combinations of materials, geometries, and print processes, the companies said.  

“We’ve partnered with Raytheon Technologies to deliver an intuitive and accessible tool that will help engineers quickly predict and mitigate risks,” said Jeff Robertson, Hexagon’s director of global business development.

“The ability to evaluate full laser powder bed fusion (L-PBF) parts on the mesoscale will reduce the effort to achieve part certification and thereby support industrialisation of metal 3D printing.” 

The software will be made available to a range of companies engaged in additive manufacturing, and will be complementary to Hexagon’s existing Simufact Additive tool. Similarity to the existing user interface should allow easy integration into existing manufacturing processes without the need for extensive training, the partners said.  

“By combining our additive manufacturing expertise with Hexagon’s, we’re bringing a solution to market that helps manufacturers with all levels of experience make better products with greater efficiency,” said David Furrer, Pratt & Whitney senior fellow for materials and processes.

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