High component quality through 3D print simulation in Additive Manufacturing. From topology optimization to process simulation.
Simulation software for 3D printing and Additive Manufacturing
Ansys software supports you in the production of high-quality AM components. Optimize your process parameters to minimize distortion effects and achieve an ideal design.
Introduction to simulation in additive manufacturing
Explore and evaluate the various possibilities of the AM manufacturing processes by using simulation. Identify the critical points of components and, thus, avoid waste by early adjustments to the component design or the printing process.
3D printing
In recent years, 3D printing has been discovered by the industry and has become a real area of interest. Additive components are not only used in the automotive and aerospace industries; small and medium-sized companies are also increasingly relying on additive manufacturing. The advantage is obvious: prototypes as well as production parts can be manufactured within a very short time - usually within a few days - without the manufacturing of expensive moulds. The integration of many functions into one component or the combination of entire assemblies into one additive part can also save a lot of time and money during the entire process chain.
Estimated Market Growth until 2023
Metal 3D printing is a manufacturing method of components mainly made of powder by adding layers of tiny welding tracks (hatches). With this method, geometries can be created that are impossible to be produced conventionally or only at great expense.
Important Downloads at a glance
- Prozesssicherheit beim Metall-3D-Druck (Deutsch) (204 KB)
- Durchgängige Lösung für die additive Datenvorbereitung (Deutsch) (567 KB)
- Alles schon verpulvert? - Prozessoptimierung in der Additiven Fertigung aus Metallpulver (Deutsch) (872 KB)
- Laserstrahlschmelzen (Deutsch) (2 MB)
- Lattice-Strukturen und Prozesssimulation für die Additive Fertigung (Deutsch) (258 KB)

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Simulation for Additive Manufacturing
An important factor for cost-efficient additive manufacturing is the use of simulation software. Since incorrect prints can quickly become critical for any budget because of expensive machine running times, it makes sense to use simulations during product development to identify the critical points of the component regarding the printing process. Waste can be avoided by early adjustments to the component design or the printing process. With its simulation tools, Ansys offers the user support in optimizing the Design for Additive Manufacturing (DfAM) and ensures reduced development and production costs.
Reduction of Weight
Reduction of Design Space
Topology optimization
With topology optimization the shape of a component can be optimized considering its mechanical properties. For example, it becomes possible to design lighter components without losing stiffness. Topology-optimized lightweight components are often used in aerospace, automotive and other areas of mechanical engineering. Ansys' topology optimization offers fast calculations, a high selection of possible boundary conditions as well as surfaces that require only a minimum of post-processing.
Benefits of topology optimization



How to manufacture a topology optimized metal component?
For high component quality, it is necessary to carry out several steps carefully in data preparation. It starts with the optimal component position in the 3D printer, followed by the attachment of support structures required in metal 3D printing, and, finally, the simulation of the print job in order to avoid sources of error such as extensive stresses, distortion or coating collisions. Finally, the 3D data can be exported into a 2D layer data format.
- Orientation
- Support structures
- Distortion (incl. Predistortion)
- Stress
- Export into layer data format
How do I determine the optimal process parameters for metal 3D printing?
Process parameters precisely matched to additive materials are the key to ideal 3D printing. Only the right combination of laser power, laser speed and hatch distance guarantees success. With simulation software from Ansys, expensive investigations with prototypes can be minimized. Methods such as single bead, porosity, thermal history and microstructure prediction are used to determine optimal parameter combinations in advance.


Products for AM Simulation
Application example for developers and service providers
If you are a product developer or service provider – here you will find a practical application of simulation in additive manufacturing.
CADFEM seminars on the subject of Additive Manufacturing
Learn in compact seminars how to develop approaches for an optimal "Design for Additive Manufacturing" (DfAM) considering all process issues, such as component orientation, support strategy, preparation for production and thermal distortion.
CADFEM webinars focusing Additive Manufacturing
Our free webinars will provide you with an overview of the efficient implementation of additive manufacturing processes and the possibilities of component simulation.