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 problems

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

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

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

• Compare different machine settings
• Find minimum layer time necessary for thermal stability
• Find nesting for thermal stability

Identification of critical areas in parts

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

Extremely fast prediction of temperatures

• 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

Experimental calibration

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

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)