Stress prediction for a ded ti-6al-4v impeller
Ti-6Al-4V impeller deposited using a laser-hotwire DED system. Image courtesy of Lockheed Martin.
Predicted Mises stress from PanX

This case study demonstrates the ability of the PanX solver to assess the suitability of different build strategies for a Laser-hotwire deposited Ti-6Al-4V impeller.

4 different build strategies are evaluated for manufacturing the impeller, based on their impact on in situ and post-process residual stress and distortion.

The baseline simulation case runs in 30mins (48 cores) and consumes 19GB of RAM.

The findings of the study were presented at TechConnect 2023. See the full presentation here.

Heat exchanger shrink-line prediction

This case study examines the ability of the PanX solver to predict distortion related defects in complex LPBF geometries.

The solver is able to resolve all of the fine internal features of the heat exchanger, as well as the individual supports, and accurately predicts the location of the shrink-line appearing on the flange.

The FEA mesh contains 41.5M nodes and the simulation runs in 11.5 hours on a 48-core workstation.

(a) © 2023 Velo3D, Inc. All Rights Reserved. This figure is used with Velo3D permission for marketing purposes only. (b) Simulated distortion/shrink-line. 41.5M FEA nodes. Runtime = 11.5hrs on 48 core CPU.
Directed energy deposition distortion prediction
Distortion simulation of a DED component. Experimental scan (left) vs Simulation (right). Runtime = 75s on an 8-core laptop. Peak memory use = 1.4GB.

Multi-Grid Modeling is also applicable to part-scale DED modeling.

Here, PanX is used to predict distortion on a 1.25 meter tall panel manufactured using Directed Energy Deposition.

The simulation runs in 75s on an 8-core laptop.

Laser powder bed fusion distortion simulation

This validation case demonstrates the ability of PanX to simulate distortion in LPBF parts.

This geometry contains very thin features (down to the resolution of the machine), meaning that it would computationally difficult or impossible to simulate or mesh using traditional approaches.

Here, the simulation time is just 36 mins on a laptop, with a peak memory consumption of 56GB.

© 2023 Velo3D, Inc. All Rights Reserved. This figure is used with Velo3D permission for marketing purposes only. Runtime = 36 mins on an 8-core laptop.