Primary features of exaSIM™

What is it?

exaSIM™ Software is a cloud-based Additive Manufacturing (AM) simulation tool that provides metal laser sintering users with rapid insight into residual stress and distortion predictions. These predictions are used to accelerate production through informed support generation and trend analysis; reducing trial and error iterations for successful builds. exaSIM is available in GovCloud for our customers who want access within an ITAR compliant environment. The AWS GovCloud (US) is ITAR, FedRAMP and DOD SRG compliant and is ISO 9001 / 27001 / 27017 / 27018 certified.

How does it work?

exaSIM™ utilizes advanced computational solvers to predict residual stress and distortion in a layer-by-layer fashion. A user supplied STL file is automatically meshed for analysis. A strain pattern is calculated and used to simulate how residual stress and distortion evolve as the part is being built. The maximum stress components are stored and used for support generation. Upon completion, exaSIM users are provided with stress contours for their part, multiple support options and distortion before and after removal from supports.

exaSIM™ offers three operational modes for predicting distortion and residual stress: 1) Uniform Assumed Strain, 2) Scan Pattern Based Strain, and 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 taking into account scan pattern based anisotropy. Thermal strain provides the highest degree of accuracy by predicting how thermal cycling affects strain accumulation. All modes can be used to generate supports and conduct trend analyses using linear elasticity or non-linear plasticity.

Support Generation

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 are increased 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 of as-built parts. Stress and distortion values are delivered to the user using the open source Visualization ToolKit (VTK) file format. These 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 undeformed geometry and the final deformed geometry. Color maps can also be used for viewing distortion trends, final residual stress, and the maximum stress components throughout the build. 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 blade crash failures.


Flexible package and payment options available


Uniform assumed strain
Uniform assumed strain simulations
User-customized material assumptions
Realtime simulation progress
Community forum
Email support
* 2 months free with prepaid annual subscription


Uniform assumed strain and scan pattern based strain simulations
All features of base package
Scan pattern dependent strain simulations
More S3 storage
More user logins
* 2 months free with prepaid annual subscription

exaSIM Complete

Thermal strain, uniform assumed strain, and scan pattern based strain simulations
Coming Soon
All features of Advanced package
Thermal strain simulations
More S3 storage
More user logins
* 2 months free with prepaid annual subscription

exaSIM Enterprise

Enterprise scale, priority support, and personalized training
Contact us
Additional concurrent simulations
More than 5 user logins
3TB+ S3 storage
Dedicated technical success manager

Feature Comparison

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

Auto-generated Supports (STL)
Distortion Trends (VTK)
Residual Stress Trends (VTK)
Uniform Assumed Strain
Scan Pattern Dependent Strain
Thermal Strain
Concurrent simulations* 1 1 1 customizable
User logins Unlimited Unlimited Unlimited Unlimited
Community forum
Email support
User group participation
Text message alerting for simulations
Real-time simulation progress
Cloud based access
Allocated S3 storage limit 1 TB 2 TB 3 TB customizable
User-customized material assumptions
Thermophysical material database** n/a n/a 1 customizable
Priority email support
Phone support
Onsite training Available
Dedicated technical success manager Available
* Concurrent simulation limit can be increased for $700/month or $7,000/year per instance
** Thermophysical material databases can be added for $200/month or $2,000/year per material

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.

Still have questions?

Schedule a demo, request more information, or connect with our team.