ANSYS Additive Suite Capabilities

ANSYS Additive Science

ANSYS Additive Science can be run inside or outside of ANSYS Workbench and is specifically designed for these users:

  • Metal AM experts looking to optimize and fine-tune their machine and material parameters.
  • Material scientists working to develop new metal powders and metal AM materials and material specifications.
  • Powder bed machine manufacturers seeking to optimize their machine designs.
  • Metallurgists in aerospace, biotech, automotive OEMs and organizations interested in AM capabilities.

This tool helps users determine the best process parameters for any machine/material combination, and ensures the achievement of the highest integrity parts, as well as the expected microstructure and physical properties.


  • Proprietary mathematical algorithms produce results that are orders of magnitude faster than competing finite element solutions.
  • Simulations are based on exact scan vectors from a build file or user-defined scan patterns.
  • Custom-curated databases include non-linear, temperature-dependent thermophysical properties for each material (as a function of physical state).

Why use ANSYS Additive Science?

  • Determine optimum machine/material parameters.
  • Control microstructure and material properties.
  • Manufacture using new metal powders faster and more efficiently.
  • Reduce the number of experiments needed to qualify components.
  • Mitigate risk while accelerating innovation.
  • Create process qualification procedures based on comparisons between simulation-predicted “correct” — and sensor-measured “actual” — machine behavior.


Analyze Porosity and Meltpools
Enables the analysis of meltpool-scale phenomena for full-size components, and provides detailed thermal history and microstructure information.
Allows users to run single-bead simulations for quick evaluation of meltpool shapes and sizes, using different process-parameter combinations (e.g., scan speed and laser power).
Determines the percentage of porosity in a part due to lack of fusion (for selected sets of process parameters).

Predict Sensor Measurements
Predicts sensor measurements based on machine/material combinations for a variety of thermal sensors, including stationary, moving point, IR camera and pyrometer sensors for powder bed metal AM machines.

Predict Thermal History
Calculates temperature history and offers the ability to track phase transformations from powder to liquid to solid — through the entire build process — allowing users to control the final properties of the printed part.

Predict Microstructure
Predicts the grain size, texture and segregation in each part based upon process-parameter inputs, including build plate temperature and laser power, speed and scan strategy.
Predicts material microstructure, enabling users to control anisotropic mechanical properties, such as material strength and elastic modulus.

Run Parametric Studies
Utilizes the power of ANSYS Workbench to evaluate hundreds or thousands of criteria virtually.

Track Phase Transformation
Uses chemistry-dependent and thermal-gradient-dependent phase change details to predict thermal history, sensor output and microstructure — all with unparalleled accuracy.

ANSYS Additive Science

Additive Process Simulation

ANSYS mechanical print simulation is an ANSYS Mechanical feature, specifically designed for users familiar with this environment. Mechanical print simulation facilitates the set up and solving of print simulations, while offering maximum flexibility for adjusting workflow settings as needed.

Why use ANSYS mechanical print simulation?

  • Enables Simulation of AM processes within the Mechanical environment.
  • Enables Facilitation physics-based topology optimization with built-in manufacturing constraints for AM.
  • Generates efficient lattice structures.
  • Simulates the thermal-mechanical build process for accurate prediction of part distortion and stresses.
  • Provides simple input of process parameters to define the AM build process.
  • Enables use of nonlinear and temperature-dependent material properties (with no inherent strain assumptions).
  • Provides full-user access to process settings for customization.
  • Efficient HPC performance scaling with ANSYS HPC products.


Predict Distortion
Offers insight into how parts will distort during a build.
Provides visualization that allows users to evaluate how their assumptions of distortion and residual stress effect as-built parts, to enable the successful selection of part orientations and support strategies.
Enables the visualization of the differences between the original, un-deformed geometry and the final deformed geometry, before and after removal from supports.

Predict Stress
Predicts stress trends, final residual stress and maximum stress locations throughout the build.
Delivers graphical visualization of layer-by-layer stress accumulation and high-strain regions throughout the build.

Run Parametric Studies
Utilizes the power of ANSYS Workbench to evaluate hundreds or thousands of criteria virtually.

ANSYS Mechanical Print Simulation