Simulation of additive manufacturing processes for the production of metal components

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Additive Manufacturing technologies are gaining interest due to rapid design and manufacturing. However, challenges like component failure and post-production failures exist. A numerical analysis tool is developed using cloud-based HPC simulation to forecast AM process results.

Start date: 01/11/2015

Duration in months: 18

Problem Description

Additive Manufacturing technologies are gaining significant interest due to their ability to quickly design and manufacture prototypes and products. Predicting physical properties via multi-scale/multi-physics simulations can optimize final product quality before production.




Addictive Manufacturing technologies face challenges like component failure due to layer deposition issues, which can occur at multiple points during the fabrication process and can also lead to post-production failures of seemingly complete parts.

Innovation results

A cloud-based HPC simulation tool for predicting AM process results was built, predicting component stress and product deformation. This approach captures the complex manufacturing process, identifying parameters affecting final product quality and requiring tight control before production begins.

Business impact

HPE obtained optimized AM solutions, resulting in reduced time-to-market, and build failures. The results are expected to increase HPE's market share by 50% and reduce costs by €90k per year. EXEMPLAR can offer the technology under an SaaS model for a potential annual turnover of €125k.

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