Amphyon
Характеристики
Производитель
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Additive Works
Amphyon
Simulation-based process preparation software for Laser Beam Melting
Additive Works provides software solutions aiming at a "first-time-right" additive manufacturing process by integrating new analysis and simulation tools into the process chain of Laser Beam Melting processes (LBM, SLM, DMLS, Metal 3D Printing). Driven by current requirements and challenges of industrial additive manufacturing, the software suite Amphyon aims to significantly reduce pre-processing costs and take metal AM to the next level of automation.
The ASAP Principle
The ASAP-Principle describes four ideal steps on the way to a stable, efficient and reliable process chain: Assessment, Simulation, Adaption and the Process itself. By examining all possible build-up orientations with respect to economical and physical aspects of the process on the Assessment stage, both, limitations of the design and optimal orientations can be calculated. The integration of simulation based, automatic generation of optimized support structures and fast process simulation tools into the pre-processing chain on the Simulation stage ensures geometric accuracy and increases process stability while tremendously reducing the costs of process preparation. Finally, on the Adaption stage, process parameters should be controlled with respect to thermal and mechanical aspects via hatch re-orientation and parameter adaption. After going through these steps of pre-processing, on the last stage the first-time-right process itself concludes the ASAP-Principle
Assessment

Examiner
Application specific optimization of build-up orientation based on the analysis and evaluation of required
Support volume
Distortion susceptibility
Simulation

Supports
Generation of optimized support structures that adjust support perforation and interfaces between part and support structure according to the loads that occur during the build-up process (MPS-Module required).
Design-space definition

Support creation



Mechanical Process Simulation
Fast mechanical simulation of the laser beam melting process, calculating the residual stress and distortion fields on regular desktop hardware.
Experimental calibration




(Additional modules required)

Thermal Process Simulation
Fast thermal simulation of the laser beam melting process, calculating the temperature history and field on regular desktop hardware.
Analysis of printjob setup



Predeformation
One-click solution to pre-compensate residual distortions by adapting the build-up geometry (MPS-Module required).
Compensation of build distortions




Additive Works believes, that process parameters like scan speed or laser power should be adapted to and specified by the properties of the application. Since scan parameters in additive manufacturing processes constitute a major know how of both, technology provider and technology users, the innovative and patented technology of Additive Works is working on a level that respects aspects already optimized.
Additive Works provides software solutions aiming at a "first-time-right" additive manufacturing process by integrating new analysis and simulation tools into the process chain of Laser Beam Melting processes (LBM, SLM, DMLS, Metal 3D Printing). Driven by current requirements and challenges of industrial additive manufacturing, the software suite Amphyon aims to significantly reduce pre-processing costs and take metal AM to the next level of automation.
The ASAP Principle
The ASAP-Principle describes four ideal steps on the way to a stable, efficient and reliable process chain: Assessment, Simulation, Adaption and the Process itself. By examining all possible build-up orientations with respect to economical and physical aspects of the process on the Assessment stage, both, limitations of the design and optimal orientations can be calculated. The integration of simulation based, automatic generation of optimized support structures and fast process simulation tools into the pre-processing chain on the Simulation stage ensures geometric accuracy and increases process stability while tremendously reducing the costs of process preparation. Finally, on the Adaption stage, process parameters should be controlled with respect to thermal and mechanical aspects via hatch re-orientation and parameter adaption. After going through these steps of pre-processing, on the last stage the first-time-right process itself concludes the ASAP-Principle
Assessment


Examiner
Application specific optimization of build-up orientation based on the analysis and evaluation of required
Support volume

- Calculates required support volume for all orientations
- Customizable overhanging angle and support density

- Estimates the built time for all orientations
- Considers support volume and recoating time

- Calculates the accessibility of the model surface
- Highlights problematic areas
Distortion susceptibility

- Calculates the distortion tendencies for all orientations
- Fast simulation based estimation within minutes

- Combination of accessibility and support areas
- Helps to avoid problems with support removal
- Displays regions with potential surfaces finishing problems
Simulation


Supports
Generation of optimized support structures that adjust support perforation and interfaces between part and support structure according to the loads that occur during the build-up process (MPS-Module required).
Design-space definition

- Easy 3D definition of the design-space
- Can be generated by e.g. overhanging angle criterium
- Allows externally created STLs as design-space

- Uses default support parameters as initial values
- Implements physics-based optimization
- Calculates optimal parameters in support-space
- Ensures process stability
Support creation

- Support model geometry will automatically be created
- Resulting supports can be exported as 2D STL file

- Support structure is fragmented for easy removal
- Wall perforation for good powder removal
- Outer contour can be added for increased stability

- Easy removal of the support structure from part
- Interfaces are adapted to avoid delamination

Mechanical Process Simulation
Fast mechanical simulation of the laser beam melting process, calculating the residual stress and distortion fields on regular desktop hardware.
Experimental calibration

- Calibration based on an easy to print small geometry
- Takes simple optical measurement as input
- Fully automated routine
- No complex micro-scale simulations necessary

- Cutting edge meshing algorithms for accurate surface
- Creates homogenized elements for filigree supports
- No Finite-Element knowledge necessary
- Easy to auto-mesh function

- No dependency on meshed layer thickness
- Reproducable result values with different meshes
- Simulation on coarse meshes possible for large structures

- Easy setup with OpenCL or CUDA
- Optimized for CAD workstation hardware
- Fast calculation of real parts and support structures
- Calculates on CPUs or GPUs

(Additional modules required)
- Compensation of distortions with Pre-deformation Module
- Optimization of supports with Support Generation Module

Thermal Process Simulation
Fast thermal simulation of the laser beam melting process, calculating the temperature history and field on regular desktop hardware.
Analysis of printjob setup

- Get build time estimation
- Estimate thermal behavior of print job
- Identify process phases with very high build rates
- Consider multi-laser systems
- Identification of suitable process parameters

- Find minimum layer time necessary for thermal stability
- Find nesting for thermal stability

- Analyze macroscopic thermal field throughout process
- Identify where additional supports may be required
- Get fast overview of critical areas of design

- Calculates on CPUs or GPUs
- Optimized for CAD workstation hardware
- Analyze even very complex structures within minutes
- Run different setups without the need for long computations

- Easy improvement of presets if measurements exist
- Avoidance of overcomplex and unknown model parameters
- Standardized test specimen


Predeformation
One-click solution to pre-compensate residual distortions by adapting the build-up geometry (MPS-Module required).
Compensation of build distortions

- Modifies STL using distortion values after buildup
- Compensates irreversible process distortions

- Modifies STL using final distortion values
- Compensates irreversible distortions by stress relaxation
- Cutting direction and heat treatment can be considered

- Modifies STL of the support structure
- "Ready for manufacturing" supports with pre-deformation

- Configurable degree of refinement
- Adaptive method based on local deviation

- Export of deformed models and supports as STL
- Analysis of the distorted shape (ext. software required)
- Direct comparison with 3D scans (ext. software required)
Additive Works believes, that process parameters like scan speed or laser power should be adapted to and specified by the properties of the application. Since scan parameters in additive manufacturing processes constitute a major know how of both, technology provider and technology users, the innovative and patented technology of Additive Works is working on a level that respects aspects already optimized.