Metal Additive Manufacturing enables the efficient production of parts which would otherwise be difficult or impossible to manufacture using conventional means. First developed in the 1990’s, machines employing Selective Laser Sintering (SLS) and related additive processes can now produce complex parts rapidly, and with a high level of precision and quality. Such parts may approach similar levels of density and strength as wrought metal, but there remain many difficulties in the step from ‘art to part’. Achieving right-first-time printing, consistent quality and repeatability across a wide range of parts is a significant challenge, and even multi-million dollar SLS machines may produce poor quality parts with unacceptably high build failure and scrappage rates.


Fortunately many of these problems may now be predicted and avoided or mitigated through the use of the latest generation of AM process simulation tools. ANSYS’ best-in-class solutions for additive manufacturing enable simulation at every stage, from topology optimization through to layer by layer analysis of the AM print process, including complex thermo-mechanical effects, melt-pool dynamics, with porosity and microstructure prediction.

Key Topics:

This seminar will present an overview of ANSYS’ solutions for AM product design and process simulation, including:

·        Physics based topology optimization and part validation

·        Design of optimal support structures with the effect of part orientation

·        Metal AM process simulation with part distortion prediction and compensation

·        Prediction of blade crash risk, cracking and other build failures

·        Tuning of SLS machine settings and parameters

·        Effects of heat treatment steps

·        Part density, fusion, porosity and microstructure



Presenters Profile:

Dr Sankar Seetharaman. Sankar holds his PhD from National University of Singapore (NUS). During his doctoral and post-doctoral research stay at NUS, he has developed a keen interest on process-structure-property relationships in metallic materials, and published more than 40 research articles in various peer reviewed journals and conferences. Prior to joining ANSYS in 2018 he has worked with ARTC Singapore for 3 years, where his research was focused on the metal additive manufacturing of nickel-based superalloys and their microstructure-mechanical property relationships.


Mr Mukul Atri. Mukul completed his BS and MS degrees in Aerospace Engineering at IIT Kanpur with a specialization in structural mechanics. He has been working with ANSYS for over 3 years across a wide range of different industries and technologies. He is presently a specialist in simulating Additive Manufacturing processes along with DfAM.



09:00     Registration

09:15     Welcome and Introduction

09:30     ANSYS Design to Print Solutions

  • A brief overview of ANSYS Design-to-Print solutions for laser powder bed fusion which includes topics like topology optimization, lattice generation, support structure optimization

10:00     ANSYS Additive solutions for Print Process Simulation

  • Introduction to ANSYS Additive Solutions: Additive Print & Workbench Additive
  • Capabilities of ANSYS Additive Solutions to address critical build issues like residual stress, distortions, re-coater interference, part cracking

10:45     Break

11:00     New Additive Science Module and Software Demo

  • Additive Science: Single bead microstructure & Porosity Evaluation
  • Demo: Additive Print, WB additive & Additive Science

12:15     Q&A

12:30     Close

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