Digimat predictive simulation solutions for FDM technology · Material database to calibrate, store and exchange Digimat material models Mapping solutions Connection to FEA to apply

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Stratasys & e-Xstream partnership

Sandra Cherubini, e-Xstream engineering

Digimat predictive simulation solutions

for FDM technology

3Copyright 2017 e-Xstream engineering

• A global team of 60 PhDs & Engineers 100% focused on

advanced material modeling

• World leader in multi-scale material modeling with more than

500+ customers

– 400 Commercial & 100 Academic customers

– 25 out of the top 30 plastic/composite

material suppliers

– 35 out of the top 50 Auto Suppliers

– 20 out of the top 25 biggest Auto OEMs

– The major Aero Airframes & Engine OEMs

– Some major Aero Suppliers

– Major E&E Companies

• An MSC Software company since Sep 2012

• Fast growing business – 3x over last 5 years

• Part of Hexagon Manufacturing Intelligence since April 2017

e-Xstream, The material modeling company

Copyright© e-Xstream engineering, 2017 41/20/2018

DIG

IMA

T

Virtual testing lab to screen and understand the effects of material, microstructure, defect on material performances

Material database to calibrate, store and exchange Digimat materialmodels

Mapping solutions

Connection to FEA to apply multiscale methodology and account for the microstructure, defect, process at component level

Virtual allowable computation

Process modeling for plastic additive manufacturing

Since 2017,

Digimat includes

the first release of

Digimat-AM

for the simulation of

polymer 3D printing

Digimat, Award winning platform for effective and efficient

engineering of materials & structures


Digimat is used to speed-up material development,

reduce testing and improve product performance

Speed-up the development of new material systems

Reduce the cost and time of physical material testing

Optimize the weight and performance of plastics & composites structures


Digimat, one tool for any material

FDM


Digimat bridges the gap between the manufacturing

& performance via the material microstructure

Additive Manufacturing Solution


Numerical tools are needed to support the AM market

move from rapid prototyping to direct manufacturing

Source: stratasys.com

According to Wohlers Report 2016, the additive manufacturing (AM) industry grew 25.9% (CAGR – Corporate Annual Growth Rate) to $5.165 billion in 2015. The CAGR

for the previous three years was 33.8%. Over the past 27 years, the CAGR for the

industry is an impressive 26.2%Source: Forbes.com

http://wohlersassociates.com/2016report.htm


e-Xstream Eco-System for

Effective & Efficient

Engineering of AM

Materials, Processes & Parts

Modeling Solution

End-User

Material Suppliers

R&D

Printer OEMs


Digimat Additive Manufacturing Solution

Material Process Part PerformanceA

dditiv

e L

ayer

Manufa

ctu

ring

FDM/SLS

Material Engineering

Mechanical

Thermal

Electric

Process Simulation

Warpage

Residual Stress

Microstructure

Part Performance

Stiffness

Failure

Print Direction

Reinforcement

Dig

imat

Mate

rial


Stratasys is partnering with e-Xstream to offer predictive

simulation solutions tools that enable the AM value

• Software Strategy

Develop Tools that Enable the Value of AM

Value Add

CAE Analyst

AM ProgrammerOps/Manufacturing

Designer

MANUFACTURING

DesignPrinter pre-processing

Optimized FDM workflow:

PrintingPost-

processingFinal part

• MinimizedWarpage

• Masteredperformance

Simulation


Manufacturing Process Simulation

Material microstructure

Material characterization (mechanical, thermal, electrical)

Engineering of AM Parts & Systems

e-Xstream is partnering with Stratasys to support the

engineering of printed production parts

(same workflow as injection)


Digimat 2018.0 delivers the first material models of

Stratasys ULTEM™ 9085 resin and a complete process

package for Fortus 900mc

AM Simulation

Material Models

- Process

- Structural

Printer Model

Toolpath Data

ULTEM 9085 Insight part data

Fortus 900mc


High performance Advanced material models

Insight infill database

Increase the AM material

portfolio!

Materials – Digimat-MF, FE & MX support the complex

microstructure resulting from FDM printing…

Benefits

• Down select materials using virtual

engineering

• Materials engineered for the

application• Electrical conductive bead path

• High strength Composite

Reinforcement

• Low CTE Materials


Process – Digimat-AM aims at predicting warpage and

residual stresses of FDM parts

Without anchor pins – upward warpage

With anchor pins – downward warpage


Performance – Digimat-RP supports the engineering

of printed production parts


Simulating effects of warpage in an additively

manufactured composite layup tool

• Advantages of composite tools

– reduced time-to-market

– increased geometry complexity

– lowering development and manufacturing costs


Benefits

Reduce trial & errors

Gain time & money

Warpage compensation

Simulating effects of warpage in an additively

manufactured composite layup tool

Strategy

Comparison between measured warpage and

Digimat-AM warpage prediction (right)

Results

Additive manufacturing is a true

multi-scale challenge

Complex thermomechanical

loadings during the layer-by-layer

deposition of the material

Thermal history of the material

deposition

Challenges

FDM process simulation via a

multiscale approach as a function

of process setup and material

choice

Thermomechanical analysis

Predict the resulting warpage


Full printing workflow connects real world with

simulation

Part designPrinter pre-processing

Virtual printing

Warpageprediction

Physical printing

Validateprinting process

Warpage correction decreases significantly the maximum deviation

between the reference geometry and the as-printed part


Validate the FDM part design as a function of the

material and the printing process parameters

Multiscale non-linear

material model

Process data

transfered to

structural mesh

• Residual stresses

• Local printing

direction

• Local porosity

• Local filler

microstructure

As-manufactured

part performance

Strong coupling


FDM dumbbells exhibit different failure modes…


… that can be modeled and reproduced in the FEA

Conclusions

Copyright© e-Xstream engineering, 2017 251/20/2018

Digimat Additive Manufacturing Solution value proposition:

modeling to support fast ideas to the market

• Understand and optimize machine parameters

• Promote your printers with relevant parameters and materials

OEM Printer

• Design & understand material behavior

• Promote your AM grades for both process & performances

Material Supplier

• Perform advanced research

• Provide expertise and guidelines R&D Centers

• Easy access to printers and materials

• Save time & cost by printing right the first time

• Build knowledge & guidelinesEnd Users


www.e-Xstream.com

Learn more …

Thank you for your attention!

Documents

Digimat predictive simulation solutions for FDM technology · Material database to calibrate, store and exchange Digimat material models Mapping solutions Connection to FEA to apply