Primary features of exaSIM™

What is it?

exaSIM™ Software ™ is a suite of metal Additive Manufacturing (AM) simulation tools that provide critical insight into the complex physics-based phenomena associated with laser powder bed fusion. exaSIM generates practical solutionsto residual stress, distortion and build failure, enabling users to achieve part tolerances and avoid build failures without trial and error experimentation. STL files can be automatically distortion compensated to counteract the distortion that occurs during part production. Two types of support structures are automatically generated based upon residual stress predictions, enabling exaSIM users to avoid wasting time and material when placing supports. Build failure can be avoided by utilizing the automatically generated supports and the Blade Crash detection feature. For ease of use, greater speed, data storage, and rapid feature implementation, exaSIM runs in a secure cloud environment. exaSIM is available in GovCloud for our customers who want access within an ITAR, FedRAMP and DOD SRG compliant and ISO 9001 / 27001 / 27017 / 27018 certified environment.

How does it work?

exaSIM™ utilizes patent-pending computational solvers to predict residual stress and distortion in a layer-bylayer fashion. A user supplied STL file or machine build file is automatically meshed for analysis. A strain pattern is calculated using either: 1) Uniform Assumed Strain, 2) Scan Pattern Strain, or 3) Thermal Strain. Uniform Assumed Strain provides the fastest approximation by utilizing a uniform isotropic strain assumption. Scan Pattern Based Strain offers a higher fidelity solution by considering local scan pattern orientation to predict anisotropic shrinkage. Thermal strain, a simulation mode unique to 3DSIM, provides the highest degree of accuracy. Thermal strain is based upon a full-part thermal analysis, scan vector-by-scan vector. Local strain magnitude is calculated based upon the number of times a location goes through elevated thermal cycling without re-melting. Scan orientation is utilized within thermal strain to correctly predict anisotropic effects. All exaSIM modes can be used to output supports, create visualizations, conduct trend analyses, predict build failure mechanisms and provide distortion compensated STL files. exaSIM offers both linear elasticity and non-linear plasticity assumptions.

Support Generation

The maximum residual stresses that supports must withstand are predicted using 3DSIM’s Mechanics Solver and passed to the support generation module. Support structures are automatically generated based upon an algorithm which varies the support density to carry these maximum residual stresses. The resulting support structure is provided to the user, in an STL file format. exaSIM™ provides three types of support structures. Thin wall supports are single-scan-width walls that are distributed beneath each downward-facing surface below a user-specified angle. Uniform supports are placed based upon geometric considerations only. Stress-based thin wall supports are distributed such that more walls are placed in regions of higher residual stress and fewer walls in regions of lower residual stress. Thick wall supports are uniformly spaced supports where the thickness of walls increase in regions of higher residual stress. Each of these support types can be output as STL files for any exaSIM simulation.

Trend Analysis

exaSIM™ users can select successful part orientations and support strategies by visualizing the effects of their assumptions on distortion and residual stress for as-built parts. Stress, distortion, blade crash potential and high strain regions are output in the VTK file format. These files (including layer-by-layer VTK files) can be viewed in many 3rd party visualization tools, including Paraview, a free viewer. VTK files enable users to see the differences between the original un-deformed geometry and the final deformed geometry before and after removal from supports. Color maps can also be used for viewing distortion trends, final residual stress, maximum stress components throughout the build, high strain regions and potential blade crash location. These visualizations enable users to select the orientation and strategy which best meets their part design intent. By reducing maximum part stresses and distortion, users can reduce their likelihood for build failures.

Why Buy exaSIM?

exaSIM™ provides users unparalleled insight into AM-specific physics and includes features and simulation options that are not available through any other simulation provider, including predictions driven by reading metal AM machine build files and performing a full-scale thermal analysis utilizing the exact scan vectors used to build a part. Built-in features include Distortion and Stress Predictions, Support Generation, Blade Crash Detection, Distortion Compensation, and identification of High Strain locations in parts and supports.

Feature Comparison

Please contact us if none of the packages offered match your requirements

Stress-Based Automatically Generated Supports
On-Plate, As-Built Part Distortion & Residual Stress
Part Distortion after Removal from Supports
Distortion Compensation
Blade Crash Detection
Identification of High Strain Locations
Layer by Layer Stress, Distortion & Blade Crash Visualizations
Build File Readers for Multiple AM Machines
Concurrent Simulations* 1 1 1 customizable
Compute and memory optimized servers
User logins Unlimited Unlimited Unlimited Unlimited
Community Forum and Help Page Access
Email and In-App Technical Support
User Group Participation
Real-Time Simulation Progress
Worldwide AWS Cloud Access
Dedicated Storage* 3 TB 3 TB 3 TB customizable
User-Customized Material Assumptions
Priority Support
Onsite Training
Single-Point-of-Contact Technical Success Manager Available
AWS GovCloud** Available Available Available Available
* Concurrent simulation limit can be increased for $1,000/month or $10,000/year per instance. 1TB additional storage included per instance.
** AWS GovCloud upgrade available for $5,000/year.

Frequently Asked Questions

A few questions that you might have...

Can I change plans at any time?
You may change tiers or subscription levels at any time. All subscriptions are prepaid for the month, so any increases will be prorated for the remaining days in the month. After initial signup, you can make changes by contacting support@3dsim.com.
Is credit card the only billing option?
For month-to-month plans, 3DSIM offers credit card billing only. For annual prepaid plans, we can provide for alternative forms of payment.