The ASAP Principle

The ASAP-Principle describes four ideal steps on the way to a stable, efficient and reliable process chain: Assessment, Simulation, Adaption and the Process itself. By examining all possible build-up orientations with respect to economical and physical aspects of the process on the Assessment stage, both, limitations of the design and optimal orientations can be calculated. The integration of simulation based, automatic generation of optimized support structures and fast process simulation tools into the pre-processing chain on the Simulation stage ensures geometric accuracy and increases process stability while tremendously reducing the costs of process preparation. Finally, on the Adaption stage, process parameters should be controlled with respect to thermal and mechanical aspects via hatch re-orientation and parameter adaption. After going through these steps of pre-processing, on the last stage the first-time-right process itself concludes the ASAP-Principle.

Assessment

Simulation

Adaption

Examiner

Application specific optimization of build-up orientation based on the analysis and evaluation of required Support volume, Build time, Surface accessibility, Distortion sensitivity and Post-processing effort for every orientation.

Support volume

Calculates required support volume for all orientations
Customizable overhanging angle and support density

Build time

Estimates the built time for all orientations
Considers support volume and recoating time

Surface accessibility

Calculates the accessibility of the model surface
Highlights problematic areas

Distortion susceptibility

Calculates the distortion tendencies for all orientations
Fast simulation based estimation within minutes

Post-processing effort

Combination of accessibility and support areas
Helps to avoid problems with support removal
Displays regions with potential surfaces finishing problems

Supports

Generation of optimized support structures that adjust support perforation and interfaces between part and support structure according to the loads that occur during the build-up process (MPS-Module required).

Design-space definition

Easy 3D definition of the design-space
Can be generated by e.g. overhanging angle criterium
Allows externally created STLs as design-space

Optimization

Uses default support parameters as initial values
Implements physics-based optimization
Calculates optimal parameters in support-space
Ensures process stability

Support creation

Support model geometry will automatically be created
Resulting supports can be exported as 2D STL file

Support geometry

Support structure is fragmented for easy removal
Wall perforation for good powder removal
Outer contour can be added for increased stability

Interface adaption

Easy removal of the support structure from part
Interfaces are adapted to avoid delamination

Mechanical Process Simulation

Fast mechanical simulation of the laser beam melting process, calculating the residual stress and distortion fields on regular desktop hardware.

Experimental calibration

Calibration based on an easy to print small geometry
Takes simple optical measurement as input
Fully automated routine
No complex micro-scale simulations necessary

Advanced meshing algorithms

Cutting edge meshing algorithms for accurate surface
Creates homogenized elements for filigree supports
No Finite-Element knowledge necessary
Easy to auto-mesh function

Mesh size independency

No dependency on meshed layer thickness
Reproducable result values with different meshes
Simulation on coarse meshes possible for large structures

Usage of massive parallelization

Easy setup with OpenCL or CUDA
Optimized for CAD workstation hardware
Fast calculation of real parts and support structures
Calculates on CPUs or GPUs

Basis for further modules

(Additional modules required)

Compensation of distortions with Pre-deformation Module
Optimization of supports with Support Generation Module

Thermal Process Simulation

Fast thermal simulation of the laser beam melting process, calculating the temperature history and field on regular desktop hardware.

Analysis of printjob setup

Get build time estimation
Estimate thermal behavior of print job
Identify process phases with very high build rates
Consider multi-laser systems

Identification of suitable process parameters

Compare different machine settings
Find minimum layer time necessary for thermal stability
Find nesting for thermal stability

Identification of critical areas in parts

Analyze macroscopic thermal field throughout process
Identify where additional supports may be required
Get fast overview of critical areas of design

Extremely fast prediction of temperatures

Calculates on CPUs or GPUs
Optimized for CAD workstation hardware
Analyze even very complex structures within minutes
Run different setups without the need for long computations

Experimental calibration

Easy improvement of presets if measurements exist
Avoidance of overcomplex and unknown model parameters
Standardized test specimen

Predeformation

One-click solution to pre-compensate residual distortions by adapting the build-up geometry (MPS-Module required).

Compensation of build distortions

Modifies STL using distortion values after buildup
Compensates irreversible process distortions

Compensation of residual distortions

Modifies STL using final distortion values
Compensates irreversible distortions by stress relaxation
Cutting direction and heat treatment can be considered

Modification of supports

Modifies STL of the support structure
"Ready for manufacturing" supports with pre-deformation

Automated STL refinement

Configurable degree of refinement
Adaptive method based on local deviation

Comparison of simulation and process

Export of deformed models and supports as STL
Analysis of the distorted shape (ext. software required)
Direct comparison with 3D scans (ext. software required)

Additive Works believes, that process parameters like scan speed or laser power should be adapted to and specified by the properties of the application. Since scan parameters in additive manufacturing processes constitute a major know how of both, technology provider and technology users, the innovative and patented technology of Additive Works is working on a level that respects aspects already optimized. Please contact us for more information on this field.