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ANSYS Advantage Explores Simulation for Metal Additive Manufacturing

ANSYS Advantage Explores Simulation for Metal Additive Manufacturing

Additive manufacturing (AM), colloquially known as 3D printing, offers industry an amazing chance to optimize, combine and lightweight parts.

In fact, 3D printers empower engineers to turn designs into products faster than ever. However, these printers open the door to new ways for the manufacturing process to fail.

The latest ANSYS Advantage issue shows how companies use simulation to overcome the challenges of metal additive manufacturing.

For instance, instead of relying on gut instinct or trial and error, these organizations use ANSYS Additive Print to optimize their designs for metal additive manufacturing.

Additionally, organizations can use ANSYS Mechanical’s broad Design for Additive Manufacturing (DfAM) tools to improve the design’s strength-to-weight ratio.

Simulation Addresses the Challenges of Metal Additive Manufacturing

Meet Relativity Space’s Stargate. It is the world’s largest 3D printer. It is used to print rocket parts.

Metal additive manufacturing is tricky. Parts can warp, supports can collapse and inconsistent states of matter can pool in cavities.

All these deformations can land your print in a scrap heap. As each print can cost thousands of dollars, trial and error is not an economic solution.

This is where ANSYS Additive Solutions come into play. These simulation tools help engineers ensure their designs print right the first time.

For example, Relativity Space aims to manufacture rockets on Mars using additive manufacturing. To test out this dream, it is currently printing parts on Earth and using simulation tools to optimize its manufacturing processes.

These rockets will need to fly without failure after every print. Otherwise they can risk lives and payload.

This is a considerable design challenge for Relativity Space. To see how the company has addressed this challenge, read the article in Advantage.

As for those payloads, they need to be as light as possible — to save fuel — but strong enough to survive the trip into space. As an example, look at the Taranis microsatellites from the Centre national d’Etudes Spatiales (CNES). CNES uses topology optimization tools from Mechanical to maximize the strength-to- weight ratios of its designs. To see how, read the story in Advantage.

But aerospace isn’t the only industry where a faulty print job could put lives or expensive products at risk.

In ANSYS Advantage, you will also learn about companies printing motorcycles, brake pedals, medical implants and even launch vehicles. Check out the latest issue to see how these companies ensure the quality of these additive manufactured products.