FLOW-3D AM

Simulation Software by FLOW-3D

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About

FLOW-3D AM is a CFD software that simulates and analyzes additive manufacturing processes such as laser powder bed fusion (L-PBF), binder jetting, and directed energy deposition (DED). FLOW-3D AM’s multi-physics capabilities offer highly-accurate simulations of powder spreading and compaction, melt pool dynamics, porosity formation for L-PBF and DED, and resin penetration and spreading for binder jetting processes, for analysis and optimization of process parameters.

This product is intended for

Process Engineer
Design Engineer
Computational Fluid Dynamics Engineer
Researcher

Media

Multi-material Laser Powder Bed Fusion

Micro and meso scale simulations using FLOW-3D AM help to understand the mixing of different materials in the melt pool and the formation of potential defects such as lack of fusion and porosity. In this simulation, the stainless steel and aluminum powders have independently-defined temperature dependent material properties that FLOW-3D AM tracks to accurately capture the melt pool dynamics.
Wire/Powder-based Directed Energy Deposition

In this FLOW-3D AM simulation of a wire/powder-based directed energy deposition process, powder particles and wire feed are melted onto a substrate by way of a laser. Tracks are laid next to and on top of eachother where they solidify to build a 3D part. This simulation can be used to study the influence of process parameters like laser power, powder injection rates, wires feed rates, scan speeds and material properties on fusion and subsequent mechanical properties.
Laser Powder Bed Fusion with Traversing Scan Path

This simulation is looking at a L-PBF process in which the laser transverses the substrate in zigzag pattern. The remelting that occurs between tracks can influence the microstructure of the solidified metal, so it is important to understand how to optimize hatch spacing and scan strategy to achieve desired temperature gradients and cooling rates. FLOW-3D AM provides for melt pool scale process analysis to fine tune these influencing parameters.
Binder Jetting

Binder jetting is one of the fastest growing industries in additive manufacturing with a lot of research going into droplet ejection and powder-material interactions. This simulation shows how FLOW-3D AM can be used to look at droplet impingement and capillary action within a powder bed during a binder jetting process.
Powder-based Laser Metal Deposition

This simulation of powder-based laser metal deposition (LMD) demonstrates the process of depositing Fe-304 stainless steel powder concurrently with a laser source. FLOW-3D AM can be used to investigate the effect of parameters such as laser power, scan strategy, and powder injection rate on the subsequent thermal gradients, cooling rates, and fusion conditions for multiple layers.