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Structural mechanics
Structural mechanics

Optimizing Additive Process Parameters for Metallic Materials


Training Basic

Determine optimal print parameters for the laser powder bed fusion process and influence printed component properties This training is offered as a 1-day course.

1 day

Knowledge of additive manufacturing, Knowledge of material models

Software used
Ansys Additive Suite

  • Examine any combination of machine/material parameters
  • Determine process parameters using the melt pool
  • Understand the influence of the scanning strategy on microstructure and porosity
  • Reduce the number of tests and cost


The Laser Powder Bed Fusion (LPBF) process for metals is already widely used today for the additive production of industrial components. In order to find the optimum settings for 3D printing in terms of printing speed, porosity and ultimately costs, the most important machine parameters – such as laser energy, laser speed or even hatch patterns – are determined by means of many test prints and their metallurgical examination. Supplementing these experiments with simulation of the melt pool and hatch strategy for various parameter combinations, the process can be significantly accelerated and thus development costs can be drastically reduced.

Based on theory, practical exercises and workflows you will learn a procedure to find better process parameters and scanning strategies. You will use simulation in Ansys Additive Science to investigate the influence of laser parameters on the melt pool for a wide variety of metal powders. You will simulate how the scanning strategy can influence the porosity of a component. This course is suitable for you if you have purchased a new metal powder bed machine and want to optimize the printing parameters. Also, developers of metal powder bed machines will learn how to improve their standard parameters for different materials. In addition, researchers can work on the relationship between energy density and porosity of various metal alloys.

Detailed agenda for this 1-day training

Day 1

01 Additive Science: theory at a glance

  • The Laser Powder Bed Fusion (LBPF) process
  • Challenges of developing process parameters of additive build strategies for metal powders
  • Introduction to Ansys Additive Science
  • A look behind the scenes: Thermal Solver

02 Melt pool and porosity analysis for metal powder

  • Finding: Everything depends on the process parameters
  • Supplementing experiments with a digital workflow: finding ideal process parameters for metal 3D printers
  • Workshop: Determining melt pool dimensions using single bead simulation
  • Workshop: Optimizing lack-of-fusion porosity by fine-tuning hatch spacing
  • Result evaluation: Considering energy density, keyholing and balling-up effects

03 Scan strategy dependent temperature history and microstructure analysis

  • In-process quality monitoring using a virtual thermal imaging sensor
  • Workshop: Analysis of the thermal history
  • Understanding grain evolution using Cellular Automata
  • Demo: Grain size and orientation analysis

04 Management of additive material data

  • Create simulation-ready material data by fine-tuning the thermal solver
  • Demo: Setting up your own material
  • Outlook: Material management with Ansys GRANTA
  • Outlook: Distortion simulation with Ansys Additive Print and Ansys Workbench Additive

Your Trainers

Dr. sc. ETH Manfred Maurer
Engineering Services, CADFEM (Suisse) AG, Aadorf

Placement in the CADFEM Learning Pathway

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When will I receive the final confirmation for my training booking?

Straight after you sign up, an automatic confirmation of receipt will be sent to the email addresses you provided. Once you have successfully verified the data you provided, you will receive your personalized sign-up confirmation, containing further information on course fees, the billing address, etc., by email within two to three working days.  

As soon as the minimum number of attendees has been reached, you will receive a final training confirmation containing further information. If you have booked an on-site training, we recommend that you wait until you have received this final confirmation before booking your travel and accommodation.

If the minimum number of attendees is not reached, we reserve the right to cancel the training seven days before it is due to start at the latest. We are happy to inform you on changing your booking to an alternative date. Please note that we accept no liability for hotel or travel bookings that attendees have already made.

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Training places will generally be allocated based on the order in which attendees sign up. For this reason, we always recommend booking for your desired date as early as possible.

As long as a coures still has free places, it can be booked.

At what time do the training courses begin and end?

Usually the training courses start at 9:00 am and end at 5:00 pm of the respective local time. The actual course times will be stated in the booking confirmation. Please note that, depending on the training host, there may be a possible time shift between your and the provider's local time. Therefore all local times are provided with the valid time shift to Greenwich Mean Time (GMT). 

Head of Seminars
Dr. sc. Jörg Helfenstein