Simufact Additive
Predict distortion and residual stress in metal AM — and fix them before the build starts.
Simufact Additive simulates every layer of your metal 3D print — SLM, EBM, DED or binder jetting — predicting distortion, residual stress and potential build failures before a single gram of powder is consumed. Automatically generate a compensated geometry that prints to net shape the first time.
Layer-by-Layer Build Simulation
Real-time thermal simulation of a selective laser melting build — temperature gradient, layer count and distortion updated continuously.
Simufact Additive is the dedicated simulation solution for metal additive manufacturing. It models the layer-by-layer build process at the macro-scale — capturing the essential thermal gradients, residual stress accumulation and distortion that determine whether a part will meet dimensional tolerances after printing and stress relief.
Rather than spending days on expensive build failures, engineers use Simufact Additive to identify and eliminate problems in the virtual build: adjust support structures, rotate the part orientation, change the scan strategy, and generate a compensated build geometry that contracts back to the desired shape during cooling.
The result is dramatically fewer physical build iterations, reduced support material waste and significantly faster part qualification — critical for titanium aerospace brackets, cobalt-chrome implants and Inconel turbine components where material cost and machine time are expensive. See why a dedicated manufacturing solver captures this better than general-purpose FEA.
- SLM, EBM, DED (LMD, WAAM), binder jetting processes
- Layer-by-layer thermal and mechanical simulation
- Automatic distortion compensation geometry generation
- Support structure optimisation and failure prediction
- Part orientation study for minimum distortion
- Residual stress export for fatigue and fracture analysis
- Fast “inherent strain” method for large assemblies
- High-fidelity thermomechanical method for critical parts
Technical Overview
| Solver core | MSC Marc thermomechanical FEA |
| Methods | Inherent strain (fast) + thermomechanical (accurate) |
| Process types | PBF (SLM/EBM), DED, binder jetting |
| Material DB | Ti-6Al-4V, IN718, IN625, 316L, AlSi10Mg + custom |
| Post-processing | Stress relief, HIP, hot isostatic pressing |
| Outputs | Distortion field, residual stress, compensated STL |
| Integration | Magics, Materialise, Netfabb, Nastran, CAEfatigue |
Talk to an AM Simulation Expert
We can demonstrate Simufact Additive on geometry representative of your AM parts — including your alloy, machine and build strategy.
Print Right the First Time.
Outcomes from manufacturers using Simufact Additive in production qualification.
Simufact Additive addresses every major challenge in metal AM process qualification.
Build Distortion Prediction
Predict the full 3D distortion field of the as-built part — at the end of the build, after support removal and after stress relief. Map where the part deviates from nominal and by how much.
Automatic Geometry Compensation
Simufact Additive automatically inverts the predicted distortion to generate a pre-compensated build geometry. The printed part distorts back toward the target shape — dramatically improving first-article acceptance.
Support Structure Optimisation
Evaluate support geometry, density and connection strategy. Identify supports at risk of failure during the build due to excessive thermal stress, and optimise their design to reduce material use and removal effort.
Build Orientation Study
Rapidly compare multiple part orientations and scan strategies. Identify the orientation that minimises distortion, reduces support volume and avoids high-stress regions in critical features.
Residual Stress & Fatigue Input
Full residual stress tensor exported from the build simulation. Feed directly into CAEfatigue or MSC Nastran for accurate fatigue life assessment with the correct initial stress state from the printing process.
Stress Relief & HIP Simulation
Model the complete post-processing chain — stress relief annealing, hot isostatic pressing (HIP), furnace cooling — to predict the final residual stress state and any distortion changes from thermal post-processing.
Simufact Additive integrates into your AM workflow without disrupting your existing toolchain.
Import STL or CAD, define build orientation, add supports and set machine + material parameters from the built-in database.
Run layer-by-layer thermomechanical simulation. Choose fast inherent strain for early-stage studies or high-fidelity thermomechanical for final validation.
Examine distortion maps, stress fields and support failure risk. Iterate on orientation, supports and scan strategy to minimise issues before building.
Export the compensated STL directly to your AM software (Magics, Netfabb, etc.). Print the compensated geometry and achieve net shape on the first physical build.
Simufact Additive covers all major metal AM processes used in production environments.
| Process | Full Name | Key Outputs |
| SLM / LPBF | Selective Laser Melting / Laser Powder Bed Fusion | Distortion, residual stress, compensated STL, support optimisation |
| EBM | Electron Beam Melting | Thermal gradient, distortion, residual stress in vacuum environment |
| LMD / DED | Laser Metal Deposition / Directed Energy Deposition | Bead geometry, thermal history, dilution, distortion |
| WAAM | Wire Arc Additive Manufacturing | Distortion, residual stress, inter-pass temperature effects |
| Binder Jetting | Binder Jetting + Sintering | Shrinkage prediction, distortion during sintering cycle |
Simufact Additive supports AM qualification across every sector where metal printing is used for structural components.
Titanium brackets, fuel nozzles, turbine heat exchangers. AS9100 and NADCAP process qualification support.
Cobalt-chrome and titanium orthopaedic implants where dimensional accuracy is critical for patient fit.
Inconel turbine blades, heat exchangers, cooling channels. Predict residual stress in high-temperature alloys.
Lightweight structural components, tooling inserts, conformal cooling channels in injection mould tooling.
AM service bureaux offering simulation-validated builds as a premium service. Reduce reprints, improve margins.
Universities and research institutes developing new AM materials, process parameters and post-processing strategies.
Simufact Additive slots into the full AM workflow from design through to structural sign-off.
Ready to print right the first time?
Book a demonstration and see Simufact Additive predicting distortion on geometry representative of your AM parts.
Frequently Asked Questions
Simufact Additive predicts distortion, residual stress and potential build failures in metal additive manufacturing (3D printing) before a build starts, and can automatically generate a compensated geometry that prints closer to the intended net shape.
Simufact Additive supports SLM, EBM, DED (including LMD and WAAM) and binder jetting processes.
Simufact Additive offers a fast inherent-strain method for large assemblies and a high-fidelity thermomechanical method for critical parts.
The built-in material database includes Ti-6Al-4V, IN718, IN625, 316L and AlSi10Mg, in addition to custom materials.
Yes — Simufact Additive integrates with Magics, Materialise, Netfabb, MSC Nastran and CAEfatigue.