Software

Amphyon

Simulation-based process preparation software for Laser Beam Melting: Additive Manufacturing Software Solution of Tomorrow.

Additive Works provides software solutions aiming at a "first-time-right" additive manufacturing process by integrating new analysis & simulation tools into the process chain of Laser Beam Melting processes (LBM, SLM, DMLS, Metal 3D Printing).

Driven by current requirements & challenges of industrial additive manufacturing, the software suite Amphyon aims to significantly reduce pre-processing costs & take metal AM to the next level of automation. Amphon follows the ASAP-Principle, the four ideal steps on the way to a stable, efficient & reliable process chain: Assessment, Simulation, Adaption & Process itself.




Examiner

Application specific optimization of build-up orientation based on the analysis and evaluation of required Support volume, Build time, Surface accessibility, Distortion sensitivity and Post-processing effort for every orientation.

Support Volume
  • Calculates required support volume for all orientations
  • Customizable overhanging angle and support density
  • Build Time
  • Estimates the built time for all orientations
  • Considers support volume and recoating time
  • Surface Accessibility
  • 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
  • Post-processing Effort
  • Combination of accessibility and support areas
  • Helps to avoid problems with support removal
  • Displays regions with potential surfaces finishing problem


  • Support

    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
  • Optimization
  • 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 Geometry
  • Support structure is fragmented for easy removal
  • Wall perforation for good powder removal
  • Outer contour can be added for increased stability
  • Interface Adaption
  • 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
  • Advanced Meshing Algorithms
  • Cutting edge meshing algorithms for accurate surface
  • Creates homogenized elements for filigree supports
  • No Finite-Element knowledge necessary
  • Easy to auto-mesh function
  • Mesh Size Independency
  • No dependency on meshed layer thickness
  • Reproducable result values with different meshes
  • Simulation on coarse meshes possible for large structures
  • Usage Of Massive Parallelization
  • Easy setup with OpenCL or CUDA
  • Optimized for CAD workstation hardware
  • Fast calculation of real parts and support structures
  • Calculates on CPUs or GPUs
  • Basis For Further Modules

    (Additional modules required)

  • Compensation of distortions with Pre-deformation Module
  • Optimization of supports with Support Generation Module



  • 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
  • Compensation Of Residual Distortions
  • Modifies STL using final distortion values
  • Compensates irreversible distortions by stress relaxation
  • Cutting direction and heat treatment can be considered
  • Modification Of Supports
  • Modifies STL of the support structure
  • "Ready for manufacturing" supports with pre-deformation
  • Automated STL Refinement
  • Configurable degree of refinement
  • Adaptive method based on local deviation
  • Comparison Of Simulation And Process
  • Export of deformed models and supports as STL
  • Analysis of the distorted shape (ext. software required)
  • Direct comparison with 3D scans (ext. software required)
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