Many software tools promise first-time-right additive manufacturing of your metal parts, thanks to process simulation. The NAFEMS Metal Additive Manufacturing Focus Group has looked at the current generation of tools and the methods behind them. From a collective 20+ years experience with physics-based simulation of additive manufacturing processes, we have written a document that points out the pitfalls to be avoided when getting started with this kind of manufacturing process simulation, and what to pay attention to when seeking high precision.

The slides that accompany this presentation are available on the NAFEMS Resource Centre.

About the Presenters

Sjoerd van der Veen started simulating manufacturing processes when graduating at the Delft University of Technology in 1996. He worked in the metals industry, using numerical simulation to improve processes and products. Since 2006 he has been with Airbus, where in 2010 he became the first eXpert in the field of Material Modelling and Manufacturing Process Simulation. In 2017 he co-founded the NAFEMS Working Group on Manufacturing Process Simulation, MANWG.

In Airbus, between 2011 and 2019, Sjoerd has put in place experimentally validated simulation capability for the manufacturing chains around Laser Powder Bed Fusion and Directed Energy Deposition, simulating the additive manufacturing itself, but also heat treatments and other operations that are key for the development of residual stress.

Ben Saunders graduated with a MEng degree in Mechanical Engineering from from the University of Leeds in 2004 and joined Rolls-Royce in 2005 following a short time at The Ford Motor Company. He started his career at Rolls-Royce performing finite element simulation to understand the performance of gas turbine components in service, predominantly working on the Trent 900 engine for the Airbus A380. For the last 10 years he has been leading a team of engineers focussed on developing simulation tools to aid in the understanding and optimisation of Manufacturing processes as well as deploying those tools to engineers across the Rolls-Royce business.

About the Manufacturing Process Simulation Community

The Manufacturing Process Simulation Working Group has formed an online Community for all engineers who would like to learn more about the use of virtual manufacturing tools within the product design and manufacturing cycle to improve outcomes in industrial manufacturing processes.

To find out more and get involved visit the MPS Community webpage.