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Structural mechanics
Structural mechanics
Heat Transfer

Simulating Additive Manufacturing Processes in Metal Printing


Training Expert

In this training, you will learn to use Ansys Mechanical to simulate the 3D printing process for components in order to optimize geometry, component orientation & warpage. This training is offered as a 1-day course.

1 day

Basic knowledge of Ansys Mechanical

Software used
Ansys Additive Suite, Ansys Mechanical

  • Process simulation for metallic 3D printing in Ansys Mechanical
  • Optimize component orientation and support creation
  • Best Practice: thermal-structural-mechanical coupled analysis
  • DfAM: Use of simulation results for targeted component design


The simulation of the printing process of metallic materials provides ideal support for "Design for Additive Manufacturing" (DfAM). The knowledge gained in this process can be used to improve the geometry, component orientation and support strategy. Thus, even before the first print, you will receive answers to relevant questions about product development, e.g. regarding critical deformations and stresses of the printed component. In this training, you will learn how to easily set up and evaluate process simulations for metallic 3D printing using the Ansys Mechanical Workbench Additive. For the evaluation of the results, it is important to understand the simplifications and assumptions of the simulation approach, which are necessary to achieve a reasonable solution time. In this way, you avoid problems with 3D printing and reduce costly misprints.

You work in the familiar Mechanical environment and can integrate the process simulation in Ansys Mechanical Workbench Additive as a further component in your continuous product development process. For example, you can use topology optimization directly. The "Ansys Additive Suite" license is used to edit the examples. This training is aimed at development engineers and Workbench users who want to make design decisions for additively manufactured components made of metallic materials based on target-oriented process simulations.

Detailed agenda for this 1-day training

Day 1

01 Preparation for 3D printing process simulation

  • Basic Information
  • Layer by layer or continuous strand: LPBF or DED?
  • Material data for thermal-mechanical analysis
  • Part orientation and support generation in Additive Prep
  • Export of 3D printing machine data
  • Demo: Data preparation in Additive Prep

02 Laser powder bed fusion (LPBF) process

  • The laser powder bed fusion process
  • Meshing options and connecting possibilities
  • Setup using the Additive Wizard
  • Warpage compensation
  • Workshop LPBF: 3D printing rotor component

03 Direct Energy Deposition (DED) method

  • Define print path manually or using G-code
  • Setup using the Additive Wizard
  • Workshop DED: buildup welding wave
  • Evaluation of temperature distribution, distortion and residual stresses

04 Advanced techniques

  • Identifying critical areas in post-processing
  • Simplified approach: Inherent Strain Approach
  • Calibration of the LPBF process
  • Reduce computation using Adaptive Meshing
  • Outlook Additive Science: Optimal printing parameters for the powder bed based laser melting process

Your Trainers

Sebastian Hoffmann
CAE Engineer, CADFEM Germany GmbH, Berlin
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). 

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