3D printing with advanced thermal simulation and optimised build preparation

Additive manufacturing 3D printing with advanced thermal simulation and optimised build preparation

2023-11-20 Source: Amsis 2 min Reading Time

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AMSIS GmbH

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With the further development of Genesis to the level of Genesis 4 Beta, Amsis presented the latest generation of build-job preparation and simulation software at Formnext 2023 in Frankfurt, Germany. This universal software offers new features for both equipment manufacturers as well as end users in the field of 3D printing of metals.

In the part on the left, the overheated zones were ascertained based on the simulation and marked red. The adjustment of the laser’s power based on the simulation is shown in the part on the right. The exposure areas with a higher standard laser power are marked in red. Laser power is continuously reduced in the overheated zones. The exposure areas with low laser power are shown in blue. (Source: Amsis) — In the part on the left, the overheated zones were ascertained based on the simulation and marked red. The adjustment of the laser’s power based on the simulation is shown in the part on the right. The exposure areas with a higher standard laser power are marked in red. Laser power is continuously reduced in the overheated zones. The exposure areas with low laser power are shown in blue.
(Source: Amsis)

Genesis 4 supports end users along the entire process chain of build-job preparation: importing of STL data, optimal placement and nesting of parts in the build space, generation of support structures, slicing, hatching and exporting the build-job. The USPs of Genesis 4 are the simulation-based functionalities: automatic identification of the overheated zones of a part, automatic reduction of the energy input depending on the overheating intensity, and the hatching design of the optimal orientation and sequence of the exposure paths.

Genesis 4 performs rapid thermal simulations to identify overheated zones in parts, enabling targeted energy input reduction in these areas. This process optimizes thermal management, reduces the need for support structures, and enhances mechanical material properties and surface quality of 3D-printed parts.

Gallery

Genesis 4 offers users many new tools to improve process and part quality. The functions have been optimized, accelerated, supplemented with new modules and thanks to visualization, can now be seen by the user.(Source: Amsis)

3DF hexagonal hatching patterns offer very good adaptability to the shape of the part due to the three degrees of freedom in the orientation of the scan vectors.(Source: Amsis)

Available in Classic and Innovative versions, Genesis offers functionalities for basic build-job preparation and advanced simulation-based features. Its modular structure allows integration into other software tools, benefiting 3D printing machine manufacturers by automating overheating prevention and optimizing hatching patterns for exposure paths.

Genesis 4 enhances cost-effectiveness by reducing support structures, eliminating the need for new hardware. It simplifies build-job preparation through automated processes, including importing STL data, nesting, support structure generation, slicing, thermal simulation, and energy input modulation. Its simulation-based approach automatically identifies overheated zones, replacing manual settings and adapting to material properties and part geometries.

The software introduces new 3DF hatching patterns, reducing crashes with the recoater in 3D printing by better aligning scan vectors with overhang edges. It also prevents unwanted porosity and loose powder build-up during printing, contributing to greater cost-effectiveness and efficiency in the 3D printing process chain. Compared to the previous version, Genesis 4 offers faster thermal simulation, improved visualization, automatic hotspot energy reduction, optimal orientation for minimal support structures, distortion simulation, and AI-supported defect analysis in process monitoring.

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