Ansys LPBF Simulation Guide

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Table of Contents
1. Introduction to Additive Manufacturing ................................................................................................ 5
2. AM Process Simulation in Workbench Additive ...................................................................................... 7
3. Preparing the Part for Simulation ......................................................................................................... 13
4. Using the LPBF Setup Wizard ................................................................................................................ 17
5. Workflow Through the Project Tree ...................................................................................................... 21
5.1. Create the Analysis System .............................................................................................................. 21
5.2. Define Engineering Data ................................................................................................................. 22
5.3. Attach Geometry and Launch Mechanical ....................................................................................... 23
5.4. Identify Geometries (AM Process Object) ......................................................................................... 27
5.5. Assign Materials .............................................................................................................................. 29
5.6. Apply Mesh Controls and Generate Mesh ........................................................................................ 30
5.7. Identify and/or Generate Supports .................................................................................................. 38
5.8. Define Connections ........................................................................................................................ 45
5.9. Define AM Process Steps ................................................................................................................. 49
5.10. Define Build Settings ..................................................................................................................... 53
5.11. Establish Thermal Analysis Settings (Thermal-Structural System) .................................................... 63
5.12. Apply Thermal Boundary Conditions (Thermal-Structural System) .................................................. 65
5.13. Solve the Transient Thermal Analysis (Thermal-Structural System) .................................................. 66
5.14. Establish Structural Analysis Settings ............................................................................................. 67
5.15. Apply Structural Boundary Conditions ........................................................................................... 69
5.16. Solve the Static Structural Analysis ................................................................................................ 71
5.17. Review Results .............................................................................................................................. 72
6. Advanced Topics .................................................................................................................................... 81
6.1. Using Topology Optimization for Additive Manufacturing ................................................................ 81
6.2. Using the Inherent Strain Method ................................................................................................... 86
6.3. Using AM Octree Adaptive Meshing ................................................................................................ 88
6.4. Using Variable Layer Height ............................................................................................................. 92
6.5. Understanding Machine Learning Thermal Strain ............................................................................ 95
6.6. Performing a Directed Energy Deposition (DED) Process Simulation (Simplified Approach) ............... 99
6.7. Simulating Heat Treatment after the Build ..................................................................................... 100
6.8. Capturing a Buckled Shape with Large Deflection .......................................................................... 105
6.9. Modeling a Symmetrical Part ......................................................................................................... 107
6.10. Modeling Powder with Elements ................................................................................................. 112
6.11. Modeling Clamps, Measuring Devices and Other "Non-Build" Components .................................. 114
6.12. Troubleshooting Convergence Issues ........................................................................................... 114
7. Performing a Calibration ..................................................................................................................... 117
7.1. When to Calibrate ......................................................................................................................... 118
7.2. Calibration Simulation Workflow ................................................................................................... 118
7.3. Known Limitations ........................................................................................................................ 125

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Chapter 1: Introduction to Additive Manufacturing
Additive manufacturing (3D printing) can be a cost-effective way of producing parts, especially when
making use of the design freedoms the manufacturing process enables, such as topological complexity
and the ability to print assemblies in one step.

Metal additive manufacturing is used to produce parts for aerospace, automotive, medical and other
industries. These are high-value parts that require careful design and manufacturing, and simulation
has long been used to validate the as-built part performance.

The additive process for metals introduces inherent complexities and challenges, however, such that
the process itself requires simulation to successfully produce the parts.

Additive Manufacturing Processes

Additive manufacturing (AM) is classified into a number of processes, most of which are applicable to
polymers. Two are the primary processes for fully-dense (no porosity) production of metal parts: laser
powder bed fusion (LPBF) and directed energy deposition (DED). Our focus is on modeling these
two processes.

In a laser powder bed fusion process – also known as direct metal laser melting (DMLM), direct metal
laser sintering (DMLS), or selective laser melting (SLM) – a thin layer of metal powder is deposited and
a highly focused laser beam of energy is moved over its surface in order to melt the metal powder
composing the current cross section and fuse it to the preceding layer. A solid part emerges as successive
layers are deposited and processed. The initial layer is deposited on a build plate or substrate.

In a directed energy process (DED) – also known as laser engineered net shaping (LENS), electron beam
additive manufacturing (EBAM®), or laser deposition technology (LDT) – a laser or electron beam creates
a melt pool on previously solidified material where blown powder or fed wire is introduced to add
material.

Both of these processes produce high temperatures and severe thermal gradients, leading to significant
distortion and buildup of residual stresses as the layers are deposited. The distortion can be high enough
to interfere with the application of the next layer, and the residual stresses high enough to break the
part off the build plate or off its supports, or crack the part itself. Additionally, the residual stresses will
produce more distortion when the part is removed from the build plate and its supports removed
leading to an undesirable final shape.

How Simulation Can Assist with AM Challenges

Being able to simulate these distortions and stresses during the design of the part will help prevent
failed builds and lead to better designs for additive manufacturing.

Supports are generally needed to anchor and support overhangs and other horizontal (and nearly hori-
zontal) surfaces such as the tops of holes. They are also used to control distortions and provide heat
transfer routes during the build. Supports add cost – material, build time, and removal effort – so their

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Introduction to Additive Manufacturing

use should be minimized. Simulation can be used to determine the best build orientation for a part,
best locations for supports, and support sizing requirements. Simulation is particularly powerful when
used with topology optimization to minimize overhang regions requiring supports.

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Chapter 2: AM Process Simulation in Workbench
Additive
Ansys Additive Suite is a powerful collection of tools from Ansys, Inc. dedicated to additive manufacturing
simulation. Workbench Additive is one of those tools, designed to work within the Workbench platform
and the Mechanical application.

Target Users
Target users of Workbench Additive are the engineers involved in the design and analysis of mechanical
components, not necessarily manufacturing engineers and technicians tasked with printing the parts
on the machine floor, nor the R&D researchers responsible for determining the ideal printing machine
process parameters. Current users of Ansys SpaceClaim and Ansys Workbench/Mechanical will benefit
greatly from running AM Process Simulations if they plan to use additive manufacturing to print their
metal parts.

Simulation Goals
The goal of AM Process Simulation in Workbench Additive is to predict the macro-level distortions and
stresses in parts to prevent build failures and provide trend data for improving designs for additive
manufacturing including part orientation and support placement and sizing.

The simulation is not meant to provide detailed thermal or structural results needed for prediction of
micro-level process phenomena (that is, microstructure). The simulation will also not provide detailed
guidance on the setting of the machine’s process parameters. Our complementary offerings of Ansys
Additive Print and Additive Science (within Additive Suite) are the products to use to achieve those
goals.

Methodology and Abstractions

Simulation of the manufacturing process requires that the analysis follows the build process itself: layer-
by-layer solidification of the part. Since the thermal (temperatures) and structural (distortion and stress)
physics are largely uncoupled (that is, a weak coupling), we can simulate the thermal phenomena first,
layer-by-layer, and use those temperature results in a following structural simulation.

In an AM Process Simulation, the model evolves over time; that is, elements are added. We actually
mesh the entire part first with a layered mesh (either Cartesian or Tetrahedrons) and then use the
standard element birth and death technique to "turn on" element layers to simulate the build progress-
ing. Additionally, the relevant boundary conditions also evolve such as thermal convection surfaces.
The build step is complete when all the element layers have been added (made "alive").

The analysis times and time stepping are also driven by the process parameters and are not known a
priori. These details are all handled internally during the solution.

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AM Process Simulation in Workbench Additive

Simulating the entire build process for a real part following the beam scan pattern would take enormous
compute time making it impractical. To meet our goals in a reasonable compute time – meaning much
less than the actual build time – we use the following abstractions:

Super layers: Actual metal powder deposit layers are aggregated into finite element "super layers" for
simulation purposes. Since the temperature histories of each adjacent layer is similar, this lumping ap-
proach is appropriate. Note: The real machine build time is approximately the transient thermal build
step simulation time multiplied by R^(1/3), where R is the number of deposit layers in one element
super layer.

Layer-by-layer addition: Material is added and heated all at once for each element layer. For current
generation machines and their scan patterns, this is a reasonable assumption. The in-plane thermal effects
do not contribute to the distortion as much as the build direction thermal effects. This means we do
not use scan pattern information as input.

Applied temperature: Rather than applying heat flux, the entire layer is initially set to the melt temper-
ature. The assumption is that the process parameters for the build have been set appropriately so that
(1) the developed temperature is always at or above melt (no lack of fusion) and (2) the developed
temperature does not greatly exceed melt (no keyholing).

Time step size: Large integration time step sizes are used throughout the simulation. This is sufficient
to capture the induced thermal and plastic strains driving the distortion. The localized smooth heating
and cooling curves will not be captured in detail.

Supports: Supports are represented as an orthotropic homogenized solid. While you can provide detailed
support geometry, modeling this way is sufficient to capture part distortion and obtain estimates of
support failure.

Surrounding powder: For the powder bed process, the surrounding unmelted powder need not be
explicitly modeled. Instead, the heat loss into the powder can be accounted for in a simplified approach
using a convective boundary condition at the interface between powder and solid material.

The LPBF Process Add-on and the LPBF Setup Wizard

An AM process simulation can be run using native Mechanical interface objects and working through
the project tree. For an easier approach, however, we recommend you load the LPBF Process Add-on,
accessible from the Add-ons Tab in the Mechanical ribbon. Simply click the LPBF Process button (in the
Additive Manufacturing group) to load the add-on. The button is shaded blue when the add-on is
loaded.

Click the LPBF Process tab to see the add-on's custom ribbon:

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An easy-to-use LPBF Setup Wizard steps you through all the steps required to set up a simulation. If
you are new to Ansys Workbench/Mechanical, or if you are an occasional user, we highly recommend
you use the wizard. The workflow is described in Using the LPBF Setup Wizard (p. 17). We also recom-
mend you read Mechanical Application Interface in the Mechanical User's Guide.

Even existing Ansys Workbench/Mechanical users may want to try the LPBF Setup Wizard because it's
is an excellent tool for keeping you on track and preventing you from missing a task. There are a few
advanced capabilities that are not available in the LPBF Setup Wizard, but because it does not include
a solve, you can easily modify your simulation set-up after you complete the wizard. If you decide not
to use the wizard, skip ahead to Workflow Through the Project Tree (p. 21) for the procedure.

Elements, Commands, and Interface Objects Used in AM Process Simulations

The following tables show the primary elements, Mechanical APDL commands, and Mechanical interface
objects used in AM Process Simulations. These items are well documented in our reference guides and
links are provided.

Element Description
SOLID70 3D 8-node thermal solid element (Cartesian mesh)
SOLID185 3D 8-node structural solid element (Cartesian mesh)
SOLID87 3D 10-node tetrahedral thermal solid (Tetrahedrons mesh)
SOLID187 3D 10-node tetrahedral structural solid (Tetrahedrons mesh)
CONTA174 3D 8-node surface-to-surface contact element
TARGE170 3D target segment
SURF152 3D thermal surface effect

Command Description
AMBEAM For multiple-beam printers, specifies the number of beams.
AMBUILD Specifies printer parameters for the build and other options.
AMENV Specifies the build-environment thermal boundary conditions.
AMMAT Specifies the build-material melting temperature.
AMPOWDER Specifies the powder thermal conditions.
AMRESULT Specifies AM-specific result data written to a .csv file.
AMSTEP Specifies the process-sequence steps.
AMSUPPORTS Specifies the information about supports.
AMTYPE Specifies the printing process, PBF or DED.

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AM Process Simulation in Workbench Additive

Interface Object Description

AM Bond Establishes a connection between a meshed part and a meshed support in an AM
Process Simulation.
AM Process Identifies geometries and sets global options for all AM-related objects in an AM
Process Simulation.
Build Settings Defines strain assumptions, process parameters, and build conditions related to
the additive machine, material, and process.
Cartesian Mesh Creates a layered Cartesian mesh.
Create Build to Base Sets up contact between the build and the base plate that is based on element
Contact face selections at the top of the base.
Generated Support Creates a support structure consisting of finite elements.
Layered Creates a layered Tetrahedrons mesh.
Tetrahedrons
Method Control
Predefined Support Identifies a support structure that was imported with CAD geometry.
STL Support Imports and meshes a support structure that is an STL (Stereolithography) file, of
either volumeless or solid type.
Support Group Groups Predefined Support objects and Generated Support objects.

Known Issues and Limitations

Note the following limitations:

• A Workbench Additive Manufacturing Process Simulation is not meant to be used in conjunction

with any of these features: gasket elements, fracture, and remote boundary conditions.

• Simulation of advanced items such as bolt pretension, clamps, unbolting the base plate, and
other types of conditions are not available in the LPBF Setup Wizard and must be defined in the
project tree.

• The voxelized mesh option (Cartesian Mesh with Voxelization Option), one of the three recom-
mended mesh methods (p. 30) for layered simulations, is not available on a Linux platform be-
cause the underlying voxelizer code is incompatible with Linux. Choose between a Cartesian
mesh and a layered tetrahedrons mesh.

• For a multi-part Inherent Strain simulation with either Scan Pattern or Thermal Strain strain
definition (p. 53) and a generated scan pattern (rather than a build file), scan stripes will likely
not align in the x-y direction between parts.

• On machines with AMD processors, an Inherent Strain simulation with Thermal Strain strain
definition fails by default. Workaround: Set a global environment variable of TF_ENABLE_ONED-
NN_OPTS=0 and restart the Workbench/Mechanical application.

• When using Workbench scripting to open SpaceClaim and then use Additive Prep, the Additive
tab may be missing and/or the tools in the Additive ribbon may be grayed out.

• In certain configuration scenarios, and for some .scdoc geometries that were created prior to
Release 2021 R2, if you have the Additive Prep license enabled in SpaceClaim you will not be
able to open the Mechanical Application from inside Ansys Workbench. Mechanical will begin

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 to launch and then it gets stuck at this stage. If this happens, the workaround is to do one of
the following:

– Within SpaceClaim 2021 R2 or a subsequent release, save the older .scdoc geometry as
a new file using Save, Save As, or Export from Additive Prep.

– Clear the Additive Prep license check box in SpaceClaim, perform your work in Mechanical,
and then go back into SpaceClaim to enable Additive Prep for your next session. Additive
Prep license options are accessible in SpaceClaim by clicking File > SpaceClaim Options
> License and then checking/unchecking Additive Prep.

High Performance Computing

An AM Process Simulation can be very compute intensive. We recommend you use high performance
computing using an Ansys HPC license to take advantage of more than four cores.

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Chapter 3: Preparing the Part for Simulation
There are several Design for Additive Manufacturing (DfAM) considerations to be aware of that affect
the cost and quality of your part. Variables include:

• Part design (thicknesses, overhangs, edges, holes, desired surface finish)

• Orientation on the base plate (affects time to print, number of support structures, and number
of replicate parts that can be nested on a base plate)

• Support structures (serve to stabilize part, lower deformations, conduct heat away from part,
but more supports increases print and finishing time and cost)

In particular for support structures, you should think ahead about how you will remove them.
In some cases you may even need to design tooling rails onto the part in order to be able to
hold the part while supports are removed.

Location of Supports
In SpaceClaim, under the Facets tab, use the Overhangs tool to detect where supports will be generated.
This is a very useful tool to determine, in advance, overhang locations that may need supports.

Cleanup of Facets
If you have an .stl file, be sure to clean it up to eliminate gaps and slivers before importing it into
Ansys Workbench.

Under Facets, the Check Facets and the Auto Fix tools are quick ways to find and fix problems in faceted
bodies.

Use Facets > Thickness to identify thin-walled features.

To Share Topology or Not?

The requirement that geometric bodies be meshed in uniform layers in the Z direction is unique to
additive manufacturing simulations. These uniform mesh layers must be conformal even for multi-body
parts or geometries consisting of separate part and support bodies. That is, not only must faces, edges
and vertices among different bodies to be 3D printed be aware of each other in order to share inform-
ation in the simulation, they must also be sliced into layers sharing the same step sizes in the Z direction.
Together, the part and the supports constitute "the build."

Two methods in the Mechanical application are available to achieve these uniform mesh layers, one
using a Cartesian (brick) mesh and one using a Layered Tetrahedrons mesh. Whether you share topology
between bodies in the build—or not—upstream in the CAD program depends on which of these mesh
methods you will use.

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Preparing the Part for Simulation

Use the following criteria for deciding which type of mesh method to use:

• Use a Layered Tetrahedrons mesh if:

– Your geometry has thin walled features, organic curves, and/or holes.

• Use a Cartesian mesh if:

– Your geometry is blocky or chunky without fine features or holes.

– You know you will be using AM octree adaptive meshing (p. 88) to coarsen the mesh for
reduced simulation time. (The AM Octree method is not supported with the layered Tet-
rahedron mesh method.)

– You know you will be generating supports in Ansys Mechanical. (Auto-generated supports
are not supported with the layered Tetrahedron mesh method.)

Once you've decided which type of mesh method to use, use one of the following approaches, as ap-
propriate.

• If using a Layered Tetrahedrons mesh:

– Do not share topology in the CAD program. To do this in SpaceClaim, under the Work-
bench tab, use the Unshare tool to unshare coincident topology.

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 Or use Explode Part in DesignModeler.

• If using a Cartesian mesh:

– Select all bodies that are associated with the part and the supports and share coincident
topology. To do this in SpaceClaim, under the Workbench tab, use the Share tool to
share coincident topology. See the video tutorial, Share Topology for a step-by-step guide.

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Preparing the Part for Simulation

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Chapter 4: Using the LPBF Setup Wizard
Simplify and focus your workflow using the LPBF Setup Wizard. Step through the wizard pages that are
organized into workflow tasks. Actions take place when you click Next at the bottom of each page. As
you progress through the steps, the wizard automatically adds objects into the project tree. Exit the
wizard at any time and continue setting up your simulation manually in the project tree.

Open the Wizard

First make sure the LPBF Process Add-on is loaded (p. 8).

To start the wizard, select the LPBF Process tab and then select the LPBF Setup Wizard button.

The LPBF Setup Wizard guides you in a step-by-step manner through the following steps:

1. Identify geometries

2. Generate mesh

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Using the LPBF Setup Wizard

3. Generate supports (if needed)

4. Assign materials

5. Define build settings

6. Define boundary conditions and constraints

7. Set up calibration

Refer to the in-wizard help at the bottom of each page. An example page, for generating the mesh, is
shown here:

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Assumptions and Restrictions When Using the Wizard
• You can specify only one support in the wizard. If you have multiple STL supports, or mixed
support types, you'll need to insert them in the project tree (outside of the wizard). See Identify
and/or Generate Supports (p. 38).

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Using the LPBF Setup Wizard

• Supports will be removed all at once when set up through the wizard. Removal of supports in-
dividually may be done outside of the wizard. See Define AM Process Steps (p. 49).

• Simulation of advanced items such as bolt pretension, clamps, unbolting the base plate, and
other types of conditions are not available in the wizard and need to be defined in the AM Process
Sequencer. See Define AM Process Steps (p. 49).

Close the Wizard

1. Upon completing the last page, click Finish to complete the wizard.

2. Click the X in the upper, right corner to close the wizard window.

Review Items in Project Tree

At this point, continue the simulation in the Mechanical interface. It is a good idea to review the objects
in the project tree that were created by the LPBF Setup Wizard. Select the objects in the tree from top
to bottom and review the Details view for each object to see how the options you specified in the
wizard are implemented in the project tree. Notice that a new object, the AM Process object, has been
added. Also notice the named selections for the build body, the base body, support bodies, contact
connections, and constraint nodes. Mesh objects, boundary condition objects and others have been
added or changed automatically by the wizard. You can make changes or add items as needed. If no
changes are necessary you are ready to proceed to the solution step (p. 66).

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Chapter 5: Workflow Through the Project Tree
An AM process simulation involves most of the general steps found in any Ansys analysis with some
additional steps and considerations. The workflow is described in the following sections:
5.1. Create the Analysis System
5.2. Define Engineering Data
5.3. Attach Geometry and Launch Mechanical
5.4. Identify Geometries (AM Process Object)
5.5. Assign Materials
5.6. Apply Mesh Controls and Generate Mesh
5.7. Identify and/or Generate Supports
5.8. Define Connections
5.9. Define AM Process Steps
5.10. Define Build Settings
5.11. Establish Thermal Analysis Settings (Thermal-Structural System)
5.12. Apply Thermal Boundary Conditions (Thermal-Structural System)
5.13. Solve the Transient Thermal Analysis (Thermal-Structural System)
5.14. Establish Structural Analysis Settings
5.15. Apply Structural Boundary Conditions
5.16. Solve the Static Structural Analysis
5.17. Review Results

5.1. Create the Analysis System

Ansys analysis systems are the mechanism to define physics type, analysis type, and solver type. There
are two predefined, custom systems specifically for Laser Powder Bed Fusion (LPBF) additive manufac-
turing:

• AM LPBF Inherent Strain: A structural-only system in which strains are calculated from the use
of a Strain Scaling Factor rather than from material properties and thermal loads.

• AM LPBF Thermal-Structural: A linked transient thermal analysis followed by a static structural

analysis where strains are calculated from material properties and thermal loads. For simplification,
we assume the physics are uncoupled in that data flows one-way from the thermal analysis to
the structural.

While it is possible to set up an appropriate system without using an AM custom system, we recommend
you use a custom system because several settings and options are set automatically for additive simu-
lations. The remaining steps in this workflow assume you use an AM custom system.

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Workflow Through the Project Tree

Procedural Steps
1. Open Ansys Workbench.

2. Scroll down within the list of analysis systems to the list of custom systems and double-click your
preferred AM custom system, either AM LPBF Inherent Strain or AM LPBF Thermal-Structural.

5.2. Define Engineering Data

In this step, you define the source of your materials using the Engineering Data repository for material
properties. The Engineering Data workspace is designed to allow you to create, save, and retrieve ma-
terial models, as well as to create libraries of data that can be saved and used in subsequent projects
and by other users.

An additive manufacturing simulation requires a material with a melting temperature specifically defined.
We recommend using temperature-dependent properties covering the range from room temperature
to melt temperature. For the thermal analysis portion of an LPBF Thermal-Structural simulation, the

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 Attach Geometry and Launch Mechanical

properties required are thermal conductivity, density, and specific heat. For the structural analysis we
require Young’s Modulus, Poisson’s Ratio, coefficient of thermal expansion, and a plasticity model, such
as bilinear isotropic hardening (BISO). For an AM LPBF Inherent Strain simulation, both bilinear isotropic
hardening (BISO) and multilinear isotropic hardening (MISO) plasticity models are supported.

The following popular materials for AM are provided as Ansys predefined samples in the Additive Ma-
terials library portion of the Engineering Data repository:

• 17-4PH Stainless Steel

• 316 Stainless Steel

• AlF357

• AlSi10Mg

• Co-Cr

• Inconel 625

• Inconel 718

• Ti-6AI-4V

These Ansys predefined materials are defined with bilinear isotropic hardening (BISO) plasticity models.

Note:

The material properties used to generate thermal (loading) strains are not customizable when
using Machine Learning Thermal Strain as your chosen strain definition for LPBF Inherent
Strain simulations, as specific materials were used to train the ML model. In particular, the
materials used to train the model are the same as those validated for thermal simulations in
the Additive application.

Procedural Steps
The sample materials in the Additive Materials library (within the Engineering Data repository) are
automatically available when you insert an AM custom system—either AM LPBF Inherent Strain or AM
LPBF Thermal-Structural—so if you plan to use one of the sample materials, no action is required here
and you can move to the next step.

To add your own custom material, see Material Data in the Engineering Data User's Guide. A nominal
strength should be provided at the melt temperature, as a near zero modulus and/or yield strength
could lead to convergence problems. (Ansys predefined materials take care of this internally.)

5.3. Attach Geometry and Launch Mechanical

Go directly to procedural steps. (p. 25)

Typically, you’ll have these geometric bodies in the simulation model:

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Workflow Through the Project Tree

• Part – This is the part you are manufacturing. It should be a closed volume (that is, watertight), and
should be oriented with the global Z axis as the build direction. It may be modeled either resting on
the base plate (Z=0), or elevated off the base plate by supports. Usually only one part is simulated
even if there will be many duplicate parts nested on the base plate for efficiency. (A multiplier on
the build time should be used if this is the case, as described in Machine Settings (p. 49).) The part
can be made of multiple bodies but must have boundaries that are aware of each other in order to
assure a proper conformal mesh throughout the part. This is achieved through either shared topology,
AM Bond connections, or a voxelization mesh option, depending on your meshing approach, as you
will learn later.

• Support Structures – Supports are needed to anchor overhanging part features so they do not break
away from the platform during the 3D print process because of residual stress buildup. Overhanging
features are usually those with angles less than 45° to the horizontal X-Y plane. Supports may be
modeled in several ways. Together, the part and supports constitute the build.

• Base Plate – This is the platform on which the build (part plus supports) is to be printed. It is included
in the simulation because it acts as a heat sink.

Other geometric bodies that may be simulated include:

• Powder – Modeling the powder may be useful if you will be simulating multiple parts close to-
gether on the build plate or if the part has features close together, where accounting for the
heat transfer occurring between the parts or features is important. Create a separate, closed-
volume (watertight) body to represent the powder in-between multiple parts or in-between
features of the same part. Details of how to model powder (p. 112) in the simulation are found
in Advanced Topics.

• Non-build Components – At times you may want to simulate geometry items that are present
on the build plate but that are not being 3D-printed. These items may include clamps, bolts,
measuring devices, instrumentation, etc. They may influence the heat dissipation and/or distortion
of the part being built so they need to be included in the simulation. Details of how to model
non-build components (p. 114) are found in Advanced Topics.

For your part geometry, commonly imported file types include SpaceClaim .scdoc files (non-faceted)
and stereolithography .stl files (faceted). See Attach Geometry/Mesh in the Mechanical User's Guide
for other options.

You may create the base plate and supports ahead of time in the CAD program or in a support gener-
ation tool, or wait to create those bodies in the Mechanical application (described in subsequent steps).
If supports are created in CAD, the part and support bodies should be kept as separate bodies (that is,
not merged) so that they can be distinguished as such in the AM simulation in Mechanical. Whether
you set the bodies to "share topology" in the CAD program depends on whether you will be using a
Cartesian mesh, a Cartesian mesh with voxelization option, or a layered tetrahedrons mesh in the sim-
ulation in Mechanical. See To Share Topology or Not? (p. 13) for a discussion about this topic. When
everything is imported into Workbench, you will later identify the support bodies as predefined supports.

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 Attach Geometry and Launch Mechanical

Alternatively, you may choose to not include supports when you attach the part but import the supports
separately later as .stl files.

Note:

Working with a model with supports from Additive Prep—When you have created your
model for AM simulation that includes generated supports in Additive Prep:

• If you used the recommended transfer to Workbench feature, the geometry is already
attached and you can skip the first step in the procedural steps below.

• If you did not use the recommended transfer to Workbench feature and instead
opened Mechanical directly with a saved .scdoc file:

– Mechanical recognizes the file as an AM file and launches with the AM Process
object and STL Supports automatically populated. If you had not joined the
individual supports together into one support for each part, they will be impor-
ted as many individual stl supports and it may be unmanageable to continue
on for simulation.

– With the AM Process object already in place, the LPBF Setup Wizard cannot
be used to set up this simulation. Continue setting up the simulation manually
in the project tree.

Procedural Steps
1. Right-click the Geometry cell of the Transient Thermal analysis block, and select Import. Browse
for your file and import it. (Double-clicking on the Geometry cell opens SpaceClaim.)

2. After importing geometry, double-click the Model cell (or right-click, and select Edit) of the Transient
Thermal analysis block to launch the Mechanical application. It may take a few minutes for Mechan-
ical to open and your geometry to appear in the Geometry window. (In addition to the Workbench

icon, , in the taskbar, note the icon once Mechanical opens; there are now two applications
open.)

3. Once your geometry is loaded in Mechanical, review how it is presented in the project tree.

We will use an example model to be simulated that includes an arch part and a solid support as
separate bodies comprising the build, and the base plate as another separate body.

Recall that there are different requirements for connectedness of geometric bodies depending on
the mesh method you will use:

• A Cartesian mesh method requires shared topology between the part and predefined supports.

• A Cartesian mesh method with the voxelization option may have shared or unshared topology
between the part and predefined supports.

• A layered tetrahedrons mesh method requires that there be no shared topology (that is, un-
shared topology) between the part and predefined supports.

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Workflow Through the Project Tree

To check whether your geometry has shared topology, click the Display tab and in the Edge group,
choose Color and then choose By Connection from the drop-down menu. Pink edges means that
an edge is shared by three faces which is an indication of shared topology.

In the arch with support example, the geometry in the first figure was imported from SpaceClaim
with shared topology. First notice the structure of the bodies in the project tree. The arch part and
support bodies are child objects under Build. Also, in the Graphics Window, note the pink edges at
the body interfaces when Edge Coloring > By Connection is turned on. We will mesh this model
with a Cartesian mesh method (without using the voxelization option).

The geometry in the next figure was imported from SpaceClaim with unshared topology. Notice
how the bodies are shown as independent bodies in the project tree, not as child objects under the
Build object. Also, there are no shared edges between bodies (lines are black instead of pink), indic-
ating there is no shared topology. We will mesh this model with a layered tetrahedrons mesh
method.

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 Identify Geometries (AM Process Object)

4. Once the Mechanical application opens, it is a good time to adjust the number of processors (cores)
you are using on your computer. Depending on the complexity of your model, AM Process Simulations
may be computer intensive. If you have an Ansys HPC license, access the option in the Solve group
on the Home tab and change the Cores to something appropriate for your simulation.

5.4. Identify Geometries (AM Process Object)

On the imported geometry, identify which bodies are associated with the build (part and supports, if
any) and the base plate. If your geometry from CAD does not include a base plate, use the Construction
Geometry feature to create one.

Procedural Steps
We use the AM Process object in the project tree to establish the options and assumptions appropriate
for an additive manufacturing simulation. Note that the AM Process object is available only if you have
an Ansys Additive Suite software license with Ansys Mechanical Enterprise or one of the multiphysics
bundles. If AM Process is grayed out, check your software license.

If you have inserted an AM custom system—either AM Inherent Strain or AM Thermal-Structural— as

the analysis system, or you are working with a model transferred from Additive Prep using the transfer
to Workbench feature, then the AM Process object is already added and you can skip the first step in
the procedural steps below.

1. Select the Model object in the project tree, then select the Model contextual tab on the ribbon and

then the AM Process option in the Define group. Or, right-click the Model object or in the
Geometry window and select Insert > AM Process.

Once you insert the AM Process object, certain automatic actions take place. The application auto-
matically:

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Workflow Through the Project Tree

• Displays the AM Process context tab, providing useful shortcut options specific to an AM Process
Simulation. These will be demonstrated in subsequent steps.

• Sets Step Controls in an AM Process Sequence worksheet (discussed later) and in Analysis Settings
for each analysis.

• Suppresses the calculation of thermal fluxes, nodal forces, Euler angles, volume and energy, and
other miscellaneous items to reduce the size of the results file. (Set in Analysis Settings for the
transient thermal analysis.)

2. Next you need to identify which bodies are which in the geometry you imported. Select the AM
Process object and then:

• Select the body or bodies representing the part and the supports that make up the Build Geometry
and hit Apply in the Details view. To select a body, be sure that your mode of selection is on body

(rather than on face, edge, or vertex). Use the Ctrl key while clicking
the left mouse button to select multiple entities (or click, hold, and drag). Or use named selections
as a basis for selection. The build is now shown in red.

When selecting supports for identification, select only solid support bodies and not volumeless
supports (STL Supports) that may have been imported via transfer from Additive Prep. If you want
to have the application create supports automatically, you’ll do that later. See Identify and/or
Generate Supports (p. 38) for more information about supports.

• Select the body that is the Base Plate Geometry and hit Apply in the Details view. The base is
now shown in blue. (If your imported geometry does not have a base plate, construct one using
step 3.)

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 Assign Materials

At the bottom of the Details view, the offset of the part from the base is shown as Z Location at
Top of Base. This is simply a confirmation of what the Mechanical application reads from the CAD
file.

3. To create the base plate if not imported with the CAD geometry, select the Model object and then:

• Right-click the Model object or in the Geometry window and select Insert > Construction Geo-
metry.

• Right-click the new Construction Geometry object (under Model) and choose Insert > Solid.

• In the Details panel, fields appear for you to enter overall dimensions of the base and coordinates
for the center of the top of the base. Enter values for X1, X2, Y1, Y2, Z1 and Z2. An outline is
provided to preview the dimensions. Right-click on Solid and select Add to Geometry. See Con-
struction Geometry for more information.

• To identify this newly created body as the Base Plate Geometry, highlight the AM Process object,
select the new body and hit Apply in the Details view for Base Plate Geometry.

5.5. Assign Materials

In this step, you assign a material to each geometry body, considering the following guidelines:

• All bodies comprising the build (part and supports) must be the same material.

• If you are modeling powder, use the same material as the build.

• Non-build components can be different materials.

• The base plate can be a different material.

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Workflow Through the Project Tree

Procedural Steps
When you select a geometry entity in the project tree, the Details view lists all the settings associated
with that body.

1. In the project tree under Model, expand the Geometry object to see its child objects below it. Select
the geometric entity that is the build geometry and, in Details view, change the Assignment (under
Material) to be the AM material that you want to use, either one of the Ansys predefined samples,
or a custom material you defined in Engineering Data. When you assign a material to the build, the
child objects below it (the part and supports) are also assigned that same material.

2. Select the entity that is the base plate body and change its material Assignment, as desired.

5.6. Apply Mesh Controls and Generate Mesh

Go directly to procedural steps. (p. 31)

The layer-by-layer additive printing process is simulated with element layers added one-by-one using
the element birth/death technique. As such, the mesh must have a uniform size in the build (global Z)
direction. That is, each element layer must have the same height (constant Z coordinate).

For the build, we recommend using one finite element "super layer" of elements to represent 10-20
actual metal powder layers. If your machine has a 25-micron powder layer thickness (also called deposition
thickness), your element size should be between 0.25 and .5 mm. The element sizing does not have to
be an even multiple of the deposit layer thickness. Note that the real machine build time is approximately
the transient thermal build step simulation time multiplied by R^(1/3), where R is the number of deposit
layers in one element layer. (This estimate of the real build time is provided for you in the simulation
results.)

A much coarser mesh is acceptable for the base plate because it is simply serving as a heat sink and a
fixed support in the simulation.

Three primary meshing methods/options are available for additive manufacturing process simulation,
each with their strengths and weaknesses.

• The Cartesian Mesher creates a hex mesh that approximates the geometry. Small features,
curved surfaces, and horizontal or vertical surfaces that are not multiples of the mesh size are
not captured accurately unless a small mesh size is used. The method is fast and, for most distor-
tion and residual stress predictions, is quite adequate.

The Mechanical application can automatically generate supports when a part has a Cartesian
mesh. (See Generated Supports (p. 42) in the next step.)

• The Cartesian Mesher with the voxelization option creates a voxel (cubic element) mesh for
the geometry. Small features, curved surfaces, and horizontal or vertical surfaces that are not
multiples of the mesh size are accounted for by a knock-down factor technique.

Limitations with the voxelization option:

– The voxelized mesh option (Cartesian Mesh with Voxelization Option) is not available on
a Linux platform because the underlying voxelizer code is incompatible with Linux. Choose
between a Cartesian mesh and a layered tetrahedrons mesh.

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 Apply Mesh Controls and Generate Mesh

• The Layered Tetrahedrons Mesher creates a tetrahedrons mesh that conforms to a specified
layer size. It captures the geometry well, and is useful if there are organic curves, small features,
such as holes, or thin-walled parts.

Limitations with the layered tetrahedrons mesher:

– Bodies with shared topology cannot be meshed with the layered tetrahedrons mesher.
We recommend you separate bodies into individual parts in CAD. (Use Unshare in
SpaceClaim or Explode Part in DesignModeler to do this.) See To Share Topology or
Not? (p. 13).

– The AM octree adaptive meshing (p. 88) method is not supported for parts meshed with
layered tetrahedrons.

– Auto-generated supports are not available for parts meshed with layered tetrahedrons.
You should bring supports in with your geometry as predefined supports or as a separate
.stl file.

– The model should not have other suppressed bodies.

– The mesh is not associated back to the geometry.

– This method cannot be used in conjunction with mesh controls such as Inflation, Refine-
ment, Match Control, Pinch, Face Meshing, Face Sizing, and Edge Sizing controls.

Procedural Steps
We will describe the meshing steps using the arch with support model for both the Cartesian and
layered tetrahedrons mesh techniques.

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Using a Cartesian Mesh

1. Set mesh controls for the part and support bodies. The size of the mesh is required to be the
same throughout all bodies in the build. Remember that the build requires a finer mesh than
the base plate.

a. To set mesh controls for the build, we will use a meshing shortcut designed for AM Process
Simulations. In the project tree, select the AM Process object and then select the Cartesian
Control option from the ribbon (AM Process context tab). Or, right-click the AM Process
object and select Insert > Cartesian Mesh. Notice that a Body Fitted Cartesian object has
appeared under the AM Process object and become active and that all the bodies that are
part of the build are selected.

b. In Details of the Body Fitted Cartesian object, under Definition, set the Element Size to
the desired value. (Click in the right column on the word Default to activate the text field.)

c. Under Advanced, you may choose to set the Projection Factor slider to a value between
0 and 1. The Projection Factor defines how well the mesh will fit to the geometry. A value
of 0 (default) results in cubic elements with a rough fit to the geometry. Increasing the
Projection Factor will change the shape of the elements to better fit the geometry and
may yield better results in some cases but may also result in a failed mesh. Our recommend-
ation is to leave it at 0, or close to 0, initially and then iterate from there to see the effects
of changing Projection Factor.

Important:

The Projection Factor must be set to 0 when using generated sup-

ports (p. 38).

You can apply a Coordinate System for the mesh. Typically, the default global coordinate system
is appropriate but you may want to set it to one located on the top surface of the base plate.

See Cartesian Method Control in the Meshing User's Guide for additional information about
Cartesian meshes.

2. Set mesh controls for the base plate. Highlight the Mesh object and right-click Insert > Sizing.
A Sizing object is created under the Mesh object and becomes active.

a. Select the base plate body and hit Apply in the Details view.

b. Under Definition, change the Element Size to the desired value, something that will
result in a fairly coarse mesh.

3. Finally, highlight the Mesh object and right-click Generate Mesh. If you don't like the generated
mesh you can easily go back and change element sizes, then right-click Mesh and select Update.

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 Apply Mesh Controls and Generate Mesh

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Workflow Through the Project Tree

Using a Cartesian Mesh with Voxelization Option

1. First, set mesh controls for the part and support bodies. The size of the mesh is required to
be the same throughout all bodies in the build. Remember that the build requires a finer mesh
than the base plate.

a. To set mesh controls for the build, we will use a meshing shortcut designed for AM Process
Simulations. In the project tree, select the AM Process object and then select the Cartesian
Control option from the ribbon (AM Process context tab). Or, right-click the AM Process
object and select Insert > Cartesian Mesh. Notice that a Body Fitted Cartesian object has
appeared under the AM Process object and become active and that all the bodies that are
part of the build are selected.

b. In Details of the Body Fitted Cartesian object, under Definition, set the Mesh Using
Voxelization option to Yes. (This option is set to No and is grayed out on a Linux operating
system.)

c. Under Advanced, set the Element Size to the desired value.

d. Adjust the Wall Thickness, as needed, according to the single-bead thickness set by your
machine.

e. Adjust the Subsample Rate, as needed. For most cases, we recommend using the default
value of 5.

The part will be meshed with cubic elements. Each cubic element is divided into sampling
regions to determine density of material within that element. These are used as material
property knockdown factors. A Subsample Rate of 5 (default) = 5 x 5 x 5 = 125 subdivisions.
Subsample Rate affects the accuracy of element density.

2. Next, set mesh controls for the base plate. Highlight the Mesh object and right-click Insert >
Sizing. A Sizing object is created under the Mesh object and becomes active.

a. Select the base plate body and hit Apply in the Details view.

b. Under Definition, change the Element Size to the desired value, something that will
result in a fairly coarse mesh.

3. Finally, highlight the Mesh object and right-click Generate Mesh. If you don't like the generated
mesh you can easily go back and change element sizes, then right-click Mesh and select Update.

Important:

The mesh generated using the voxelization option is not fully associated to the part
geometry. Loads scoped to the part body (face, edge, vertex) are not possible. However,
loads scoped to the mesh of the part (that is, FE loads) are valid. These can be defined
with named selections or manual selection.

Consider using AM octree adaptive meshing to reduce simulation time if your part has bulky or
blocky areas, especially near the bottom (that is, near the lower layers). The AM octree method
of nonlinear mesh adaptivity coarsens the mesh in previously deposited layers, resulting in a re-

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 Apply Mesh Controls and Generate Mesh

duction in total element count. The method is only available for parts that have been voxelized.
See Using AM Octree Adaptive Meshing (p. 88).

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Workflow Through the Project Tree

Using a Layered Tetrahedrons Mesh

To use a layered tetrahedrons mesh, in Ansys Mechanical:

1. Click Mesh in the Tree Outline, right-click and select Insert > Method. Select the build
geometry—use the Ctrl key to select multiple bodies, for example if you have part and
predefined support bodies—and in Details view, click Apply. In Details under Definition,
change the Method to Layered Tetrahedrons.

2. In the Layered Tetrahedrons Details view, set the Layer Height as desired. Note that
the layer height should balance the need to capture features and the need for a reasonable
simulation run time. The recommended setting for this "super layer" is 10-20 times the
size of the machine deposition thickness.

Most of the remaining advanced settings in the Details view have adequate defaults.

3. Click the Mesh object, and in its Details view, set the Element Size. Element Size can be
less than, equal to, or greater than the Layer Height but should not be greater than 6
times the Curvature Min Size. Consider starting with an initial value slightly larger than
Layer Height. This allows individual elements to have non-Z-direction edge lengths longer
than Layer Height while still keeping the overall Z-direction height at Layer Height.

Initially, use the default settings for the remaining options. The default settings are cus-
tomized for additive process simulations only when the AM Process object is in the project
tree so it is always best to add the AM Process object before meshing. Review the following
global mesh settings and change them as necessary:

Defaults
Element Order Quadratic (default if the AM Process object is in the project tree).
Note that mid-noded elements will be generated, but the mid-nodes
will be kept straight and will not conform to the geometry.
Element Size Can be greater than Layer Height. The Element Size should not be
greater than 6 times the Curvature Min Size specified. The mesh
quality reduces as the Element Size / Curvature Min Size ratio
increases.
Sizing
Use Adaptive Sizing No (default if the AM Process object is in the project tree)
Capture Curvature Yes (default if the AM Process object is in the project tree)
Curvature Min Size Dynamically calculated to be 0.3 times the Layer Height (specified
in Details of Layered Tetrahedrons mesh method object). Used by
the mesher to generate a surface mesh before the slice layers are
generated, hence this min size drives the resolution of the mesh.
The min size should be decided based on the features that are to
be resolved and the Layer Height. A recommended value is 1/4 to
1/3 of the Layer Height.
Curvature Normal 27 (default if the AM Process object is in the project tree). The
Angle recommended range is 18 to 36. Use a lower angle if the model has
small features like holes and fillets that you want to preserve.

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 Apply Mesh Controls and Generate Mesh

Defeature Size Dynamically calculated to be 10% of the Curvature Min Size. Used
to define the default value for sliver face height. Based on the model,
you might be required to increase it. We do not recommend using
a value greater than one-half of the Curvature Min Size.

Understanding the approach that the layered tetrahedrons mesher uses may be useful if
you are not satisfied with the meshes being generated. After experimenting with the
mesh settings described here, if you are still not happy with the tetrahedrons mesh, con-
sider adjusting Relative Tolerance, Inflate Relative Tolerance, and Sliver Triangle Height.
Care must be taken to ensure that the layer slices cut the geometry in such a way as to
avoid thin slices. Thin slices may cause the mesher to struggle or result in poorly shaped
elements. Usually adjusting the mesh Layer Height or increasing Relative Tolerance will
lead to a higher quality mesh. Refer to the Layered Tetrahedrons Method Control in the
Meshing User's Guide for further information.

4. Next, set mesh controls for the base plate that will produce a much coarser mesh. Highlight
the Mesh object and right-click Insert > Sizing. A Sizing object is created under the Mesh
object and becomes active.

a. Select the base plate body and hit Apply in the Details view.

b. Under Definition, change the Element Size to the desired value, something that
will result in a fairly coarse mesh.

5. Finally, highlight the Mesh object and right-click Generate Mesh. If you don't like the
generated mesh you can easily go back and change element sizes and settings, then right-
click Mesh and select Update.

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Workflow Through the Project Tree

5.7. Identify and/or Generate Supports

Go directly to procedural steps. (p. 40)

Supports may be imported with your geometry, you may import them as a separate .stl file, or you
may generate them directly as elements in Mechanical, or some combination of the three.

• Predefined Supports are supports that are imported with your geometry and you will need to
identify them as such.

• STL Supports are supports imported as .stl files or transferred in automatically from Additive
Prep using the transfer to Workbench feature. STL supports are generally volumeless (that is,
not watertight), thin-walled structures created with Additive Prep or other support-creation tools.
The thin, intricate support walls that may include perforations are made of many small facets.
We use a voxelizing technique, similar to that used in Additive Print, to account for this. The
mesh is generated with cubic elements that are internally divided into subdivisions for sampling
the presence of material to determine the overall densities of the elements. These, in turn, are
used for the material knockdown factors.

STL support files must be in millimeters. Furthermore, with STL supports, element size is set by the
mesh criteria used for the part. It is for this reason that you must mesh the part before, or at the
same time as, meshing the STL support. If you used a Cartesian mesh, the element size uses the
value you specified for Build Element Size. (Element size may be slightly smaller than the Build
Element Size in certain cases.) If you used a layered tetrahedrons mesh for the part, the element
size will be the value you specified for Layer Height.

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 Identify and/or Generate Supports

• Generated Supports are available only for parts meshed with Cartesian mesh (with voxelization
option equal to yes or no). These supports generated by the Mechanical application are either
automatically detected or user-defined. For automatic detection you specify an overhang angle
(the default value is 45° to the horizontal X-Y plane) under which supports will be created. For
user-defined supports you select individual element faces under which supports will be created.
Supports are generated as elements vertically straight down from the overhanging portion of
the build to the base, or to a lower portion of the model if it is in the way.

We Treat Supports as Homogenized Solids

In additive machines, supports are printed with the same material as the part but as thin walled structures
with less mass than the part. In the simulation we model the supports as an equivalent "homogenized"
solid rather than as thin-walled structures. Regardless of whether the supports are predefined, automat-
ically generated, or imported as .stl files, their properties will be scaled down to account for this
homogenization technique. Affected properties are elastic modulus, shear modulus, yield strength,
density, and thermal conductivity.

Scaling down properties is done automatically for STL supports. For predefined and generated supports,
you will do this in one of three ways:

• Specifying an overall multiplication factor. This factor is the ratio of the actual support area to
the area of the solid area. For example an overall multiplier of 0.33 will adjust the properties of
the supports to be a third of that of the part material.

• Specifying individual multiplication factors for each orthotropic direction of each material property.

• Specifying wall thickness (T) and spacing (L) for block-type supports, commonly output from
support generation tools. In this method, we calculate the equivalent homogenization factor for
you.

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Workflow Through the Project Tree

Procedural Steps
Supports are identified and/or added using the Supports group in the AM Process context menu. As
you add supports, objects are added to the project tree under AM Process. You may want to rename
these objects to meaningful names if you have many support groups. If things get confusing as you
add supports, useful tools are the Hide Support and Hide All Other Bodies options, accessible by right-
clicking on any support object.

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 Identify and/or Generate Supports

Predefined Supports

If support bodies were included in the CAD geometry, you need to identify them as supports so
that the Mechanical application is aware of which bodies to adjust properties for, or to remove if
support removal steps are specified. To identify these predefined supports:

1. Highlight the AM Process object, and then select the Predefined Support option on the AM
Process context toolbar. Or right-click in the Geometry window and select Insert > Predefined
Support.

2. Select the support bodies (geometry selection) with the mouse, holding the Ctrl key down to
select multiple bodies (or click, hold, and drag). Click Apply. Or, choose Named Selections.

3. To scale down material properties, in Details under Support Material Settings, choose Block
or User Defined for Support Type. If choosing Block supports, specify Wall Thickness (T) and
Wall Spacing (L). If you choose User-Defined for Support Type, you may adjust the material
properties by specifying either one overall multiplier or property-by-property multipliers. These
multipliers are the ratio of geometric areas of the supports to the areas of the solid geometry,
where the areas are the projected areas in the X, Y, and Z directions.

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Generated Supports

The Mechanical application's ability to automatically generate supports is available only if the part
is meshed with a Cartesian mesh (with voxelization option equal to yes or no). When generating
supports, the application can automatically determine their locations or you can specify the support
locations.

For automatic detection of generated supports:

1. Highlight the AM Process object, and then select the Generated Support option on the
context toolbar. Or right-click in the Geometry window and select Insert > Generated Support.

2. Click the Support Group object above Generated Support and change the overhang angle,
Hang Angle, to an angle between 0 and 90°, or leave it at the default of 45°.

3. Right-click Support Group and select Detect and Generate Supports. Supports are generated
for all bodies that are part of the build. Note that an option exists to Detect Supports only
(that is, not generate supports). This is quite useful if you want to see the effect of changing
Overhang Angle. If you are satisfied with the location of supports, then select Generate Support
Bodies. Another option allows you to detect and generate supports above a particular Z location
(Detect above Z location, in Details of Support Group), allowing further control of where sup-
ports are generated.

For user-defined generated supports, you restrict the regions under which supports will be generated
by selecting specific element faces in Scoping Method:

1. Highlight the AM Process object, and then select the Generated Support option on the
context toolbar. Or right-click in the Geometry window and select Insert > Generated Support.

2. Switch to element face mode of selection , and use Ctrl-left-

click to select multiple element faces, or double-click-left to select all the elements on a surface.
Click Apply in the Details panel.

3. Right-click Generated Support and click Generate Support Bodies.

Important:

Supports are generated as elements only (that is, there are no corresponding geometric
bodies created for the new supports). When viewing geometry in the Geometry window
you won’t see the supports. You will see the support elements when you select the
AM Process object (or one of its children), or the Mesh object. Or you can use the Show
Mesh toggle button to reveal the mesh even when the Model object is
active.

More importantly, if you would like to use the supports generated in Mechanical in
your final print strategy, you will need to convert the elements to geometric bodies
for the .stl file required by the printer.

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 Identify and/or Generate Supports

STL Supports

The workflow is slightly different depending on how you add STL supports. They can be transferred
in automatically from Additive Prep or imported from an STL file. Both methods are described in
step 1 below.

1. To mesh STL supports transferred in automatically from Additive Prep:

a. When supports are transferred automatically from Additive Prep, they are not scoped to
any particular body. That is, they are not associated to the part body. In the project tree,
click to expand the Imported Supports object and then click the STL Support object. In
the Geometry window, select the body representing the part and click Apply for the Geo-
metry in the Details view of STL Support.

To import and mesh STL supports from a file:

a. Before inserting the STL Support, be sure the part is meshed and the build geometry
is identified in the AM Process object. Highlight the AM Process object, and then select
the STL Support option on the context toolbar. Or right-click in the Geometry window
and select Insert > STL Support.

b. In the Details view of STL Support, identify the source of the .stl file, either a file
(default) or a previously imported STL Construction Object. Click File Name to navigate
to the appropriate folder and select your .stl support file.

2. In the Details view of STL Support, change the Length Units, as needed. The default is milli-
meters. Most often, this is what you want.

3. Identify the STL Support Type by selecting Volumeless or Solid from the drop-down.
Volumeless (default) is for non-watertight supports such as block, heartcell, rod, or line supports
created by Additive Prep. Most often, this is what you want. Choose Solid for solid bodies that
are watertight, such as custom supports created in Additive Prep.

4. For Volumeless support type, adjust the Wall Thickness, as needed, according to the single-
bead thickness set by your machine.

5. Adjust the Subsample Rate, as needed. For most cases, we recommend using the default
value of 5.

The following figure shows a curved bar model with tree supports generated in Additive Prep
imported as an STL Support file.

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Workflow Through the Project Tree

The support structure will be meshed with cubic elements. Each cubic element is divided into
sampling regions to determine density of support material within that element. These are used
as material property knockdown factors. A Subsample Rate of 5 (default) = 5 x 5 x 5 = 125
subdivisions. Subsample Rate affects the accuracy of element density.

6. Right-click the STL Support object and select Generate Mesh to mesh the support.

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 Define Connections

7. Use the Support View (under Display) to switch back and forth among the view options of
STL View, Mesh View, or Knockdown Factors. (Or, the knockdown factors may be turned on
using Display Style in the Mesh object Details view.)

Hint: Look for the tiny icon to the left of an object in the project tree for a clue about its status.
For example, if you see a question mark next to an STL Support object, it means you have not
scoped it to a part yet (if supports were transferred from Additive Prep) or identified a file name
yet (if supports were inserted via an STL file). If you see a yellow lightening bolt, it means you
have not generated the mesh for it yet. You will see a green check-mark once you have performed
all relevant tasks.

5.8. Define Connections

Go directly to procedural steps. (p. 47)

Connections are the mechanism to ensure that the part, support, and base plate bodies in the simulation
are aware of each other and are able to share data (temperatures and displacements) across boundaries.
Two connection types that are typically used in AM simulations are Build-to-Base contact connection
and AM Bond connection.

• A Build-to-Base connection is a special case of bonded contact between the element faces on
the bottom of the build and the element faces on the top of the base.

• An AM Bond is used to connect a meshed part to a meshed support when the mesh is non-
contiguous between them. The internal means of connection is through constraint equations
that connect the support nodes to the part elements.

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Certain mesh and support combinations in Workbench Additive result in contiguous mesh between
the part and the supports, with connections created automatically, while other combinations result in
non-contiguous mesh. In these scenarios you will need to create a connection between them.

As depicted in the following table, the part/support combinations that require an AM Bond connection
are:

• When the part and/or the predefined support is meshed with layered tetrahedrons (scenarios
A, D, G, and H)

• When the part is meshed with Cartesian mesh (voxelization option = No) and STL supports are
used (scenario B). STL supports are automatically meshed with a voxel mesh. In this scenario,
we recommend you use the voxelization option to mesh the part instead, in which case the
connection is automatically created.

In the other available mesh/support combinations in the table (scenarios C, E, J, and K), the connection
between the part and support is automatically created.

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 Define Connections

Symbols used in the Mesh and Support Options table are shown here.

This mesh/support combination is available

This mesh/support combination is not available

Connection between part and support is automatically created

Manual connection between part and support is required

Procedural Steps
Defining connections between entities should be performed after they are meshed. For all scenarios,
you will need to define a connection between the build and the base plate so we will start there.

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Connection between the build and the base plate — Build-to-Base:

Highlight the AM Process object and then select the Create Build to Base Contact option on the
context toolbar.

Several things happen. You will see the contact body (red) and target body (blue) views shown in side
windows of the Geometry window. The Contact Side is defined as the element faces of the bottom of
the build (part and supports). The Target Side is defined as the element faces of the top of the base
plate. In the project tree, a Contacts object is added under Connections with a Build to Base object
underneath it. Also, named selections have been created that select the element faces at the build-base
interface (Build Contact Element Faces and Base Contact Element Faces).

Connections between part and supports — AM Bond:

If you have no supports, or connections have been created automatically (scenarios C, E, J, and K), skip
ahead to the Establish Thermal Analysis Settings (Thermal-Structural System) (p. 63) step.

To create an AM Bond connection that will connect a part to a support:

1. Create a named selection for the part: Right-click the part geometry and choose Create Named
Selection. Enter a name for the part geometry and click OK.

2. Create a named selection for the support:

a. For an STL support, right-click the STL Support object and choose Create Named Se-
lection of Generated Elements.

b. For a predefined support, right-click the support geometry and choose Create Named
Selection. Enter a name for the part geometry and click OK.

3. Right-click Connections and choose Insert > AM Bond. Using named selection as the scoping
method, choose the part named selection as the Contact, and choose the support named selec-
tion as the Target.

Consider the following guidelines for AM Bond connections:

• Do not use an AM Bond connection to connect a part or support to the base plate. Use the Build-to-
Base connection for that.

• One AM Bond connection is required for each part/support combination.

• Only one body should be selected when creating the named selection for the part.

• The identification of contact and target entities as indicated in step 3 above is appropriate for most
cases. Reversing the entities identified as contact and target will not only produce a warning message,
but will typically produce unexpected and unrealistic deformation. However, if the support mesh is
much coarser than the part mesh, say greater than 2:1 proportions, reverse the selection and make
the support the contact and the part the target.

• The internal constraint equations used to implement AM Bond connections are applied to the nodes
of only the top and bottom of the supports. This means the connections will be in the Z-direction but
not the side-to-side directions.

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 Define AM Process Steps

• The constraint equations will couple the voxel supports to the meshed body even if there is penetration
of the support into the part, such as when positive intrusion values are used when generating
volumeless supports. You may, though, see anomalies at some of these interfaces, such as temperature
higher than melt or lower than ambient, or very localized large displacements at a support-part inter-
face. The overall solution (temperatures, displacements, and stresses) over the build is good and these
local anomalies may be ignored.

• You can check the number of constraint equations that are created for each AM Bond connection by
viewing the solver output. Under the Transient Thermal system, Solution object, click Solution In-
formation. In Details view, Solution Information, choose Solver Output. In the worksheet window
shown, search on "CE connections."

5.9. Define AM Process Steps

Go directly to procedural steps. (p. 51)

The AM process is accomplished through sequential steps that dictate how consecutive solutions are
performed in the overall simulation, as follows:

Minimally, there will always be a build step in both the thermal and structural portions of the simulation
and usually there is a cooldown step. Additional steps may be added to the structural analysis to account
for the removal of supports and/or the build from the base plate as shown here:

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Separating the build from the base plate after printing releases some of the locked-in stresses, rebalancing
the part's internal forces and resulting in additional deformation in the part. In most cases, base removal
is done before support removal. It is important to understand that residual stress and distortion results
may be affected by the order in which you remove supports. The Mechanical application can simulate
any scenario of support removal. You use the AM Process Sequence worksheet to specify the desired
sequence.

Other solution steps, such as heat treatment steps and user-defined user steps, may be added as shown
here:

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 Define AM Process Steps

Heat treatment steps may be added before or after removal steps.

A user step includes a solve execution and may be added at various points in the overall sequence. In
the application, a user step effectively leaves the AM simulation environment and enters the usual
nonlinear "load step" environment. Any valid loading and load step options may be used. One example
of a user step is a bolt pretension step before the build. Another example could include a set of three
user steps inserted before the removal steps:

1. US1 - unbolting the base plate to take for heat treatment

2. US2 - entire assembly heated to near melt

3. US3 - cooldown to room temperature again

Procedural Steps
For AM Process Simulations, the Mechanical application provides an alternative to the ordinary step-
manipulation in analysis settings by using a custom worksheet called AM Process Sequence. Overall
viewing and control of the steps in your simulation is done through this Sequencer, shown below. You
can access the Sequencer button only when the AM Process object is selected in the project tree. You
can toggle the display on and off using the button any time the AM Process object is selected. As illus-

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Workflow Through the Project Tree

trated, this worksheet enables you to view, and change, the steps for the transient thermal analysis and
the downstream static structural analysis, conveniently shown side-by-side. Note that unless you use a
Commands object, using the Sequencer is the only way to manipulate steps in an AM Process Simulation.

1. Select the AM Process object and then select the AM Process Sequence option on the context
toolbar (or click on Worksheet in the main menu bar).

2. To simulate the removal of the base or supports after cooldown,

a. Click Add Step at the bottom of the Static Structural side of the worksheet. The dropdown
will show the options available for removal, depending on your set-up (Base, Predefined
Support, Generated Support, and/or STL Support). You may reorder the steps in the sequence
using drag and drop of one step on top of another.

b. Additional options are available if you choose the base removal step. Under Static Structural,
click Analysis Settings in the project tree and select the Removal Step: Base option from
the Step drop-down. Choose a Base Removal Type, either Instantaneous or Directional.

• Instantaneous: Simulates instantaneous cutoff of all material at the base (bottom

layer of elements only).

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 Define Build Settings

• Directional: Simulates a progressive cutoff of all material at the base (bottom layer
of elements only), in which you specify the cut increment and the angular direction
for removal from the base.

Removal Step Size: Distance removed in every cut step. Cannot be 0 or a negative
number.

Removal Direction: Directional cutoff angle on the X-Y plane as measured from the
+X axis. For example, a value of 90 results in a cutoff direction in the +Y direction.

3. To add a heat treatment step, click Add Step on the Static Structural side of the worksheet and select
Heat Treatment Step. Additional steps are required to complete the heat treatment step as described
in the advanced topic Simulating Heat Treatment after the Build (p. 100).

4. To add a user step to either analysis, click Add Step on the desired side of the worksheet and select
User Step. In subsequent steps you will need to specify your step conditions, such as an extra
boundary condition, etc. If you want to insert a user step as the first step in the sequence before
the thermal build step, click Add Step and choose User Step Prior to Build.

Note:

Advanced Ansys users frequently combine Mechanical APDL commands with the auto-
matic execution of models set up in Mechanical for more precise and custom control
over a solution. For example, you may insert a Commands object under the Static Struc-
tural or Transient Thermal environment objects in the project tree. In the Commands
object Details view, there is a useful option to Issue Solve Command (either Yes (default)
or No). It enables users to better control how the commands in the Commands object
are processed relative to the step execution in the Sequencer.

5.10. Define Build Settings

Go directly to procedural steps. (p. 58)

In this step, specify the simulation and strain assumptions, process parameters, and conditions related
to the machine and the process.

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Simulation Settings
Simulation settings include assumptions about the type of simulation and the strain definition.

• Additive Process: Powder Bed Fusion. The Powder Bed Fusion (PBF) process uses thermal energy
from a laser or electron beam to selectively fuse powder in a powder bed.

• Inherent Strain (Yes or No): An option to use the Inherent Strain method (p. 86). (If you used one
of the AM custom systems (p. 21) in Workbench to set up your analysis system, this option is set
automatically for you.) If No, the AM simulation uses a linked thermal-structural system in which
strains are calculated from material properties and thermal loads. If Yes, an alternative method is
used in which strains are based on an experimentally calibrated Strain Scaling Factor. Options under
Machine Settings, Calibration Settings, Build Conditions, and Cooldown Conditions differ depending
on whether Inherent Strain = Yes or No.

If Inherent Strain = Yes (default if AM Inherent Strain custom system is used):

– Inherent Strain Definition: Assumption about strain behavior reflecting the different ways
inherent strain is calculated as an input to the structural solver.

→ Isotropic: Simplifying assumption that a constant, isotropic strain occurs at every location
within a part as it is being built. A constant Strain Scaling Factor may be used to scale
strain everywhere uniformly to account for calibration of the Mechanical application
to a particular machine/material combination.

→ Anisotropic: Uses the same average strain magnitude as isotropic strain, but it subdivides
that strain into anisotropic components in the X, Y, and Z directions based on the
Global coordinate system.

→ Scan Pattern: Uses the same average strain magnitude as isotropic strain, but it sub-
divides that strain into anisotropic components based on the local orientation of scan
vectors within the part. Scan vectors may be generated internally via a slicing function
assuming a rotating stripe scan pattern or input via a build file.

→ Thermal Strain: A method that provides the highest level of fidelity and takes thermal
cycling into account at each location within the part.

• Thermal Strain Method: Machine Learning Prediction (only method available

at this release)

Uses a machine learning model prediction of the anisotropic Thermal Strain

simulation result from the Ansys Additive application.—Thermal Strain simulations
provide the highest level of fidelity by predicting how thermal cycling affects
strain accumulation at each location within a part. The simulation follows the
full laser path on every layer, and is based on the machine process parameters
(power, scan speed, beam diameter, etc.).—The machine learning model has
been trained to predict the Thermal Strain result much faster than simulation.
It can be one to three orders of magnitude faster than Thermal Strain simulation
in Additive Print in calculating the strain that is passed to the structural solver.
Speedup increases with part size, scan area, and melt pool size. See Thermal
Strain - Anisotropic in the Additive Print and Science User's Guide.

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 Define Build Settings

• Machine Learning Model: A list of materials that were used to train the ML
prediction, in particular, the materials validated for the Additive application.
Choose the material that most closely matches your material assignment in En-
gineering Data. ML models may be based on different material properties than
those in Engineering Data. The ML models are used to generate loading strains.
Materials in Engineering Data are used for the structural analysis.

• Layer Height: By default, the program uses the Layer Height specified when meshing as the super
layer height. Occasionally you may want to increase the size of the super layer to something coarser
than what was used when you created the mesh. Use the Layer Height option here to do that. Spe-
cifying a new Layer Height does not affect the existing mesh.

Calibration Settings
Strain Scaling Factors are optional inputs that scale the inherent strains in an inherent strain simulation,
or the thermal strains in a thermal-structural simulation, by a given value. They are usually determined
from calibration experiments. Defaults are shown below for the various strain definitions:

Strain Definition Strain Scaling Factor(s) Default

Value
Thermal-Structural simulation Thermal Strain Scaling 1
Factor
Isotropic - Uniform strain in all directions Strain Scaling Factor 1
Anisotropic - Strain can be scaled based on the Global coordinate Strain Scaling Factor X 1
system
Strain Scaling Factor 1
Y
1
Strain Scaling Factor
Z
Scan Pattern - Strain can be scaled based on the local orientation Parallel ASC[a] 1.5
of scan vectors (parallel and perpendicular to scanning direction
and in the build direction) Perpendicular ASC 0.5

Vertical ASC 1
Thermal Strain - Strain can be scaled based on the local orientation Parallel ASC 1.5
of scan vectors (parallel and perpendicular to scanning direction
and in the build direction) Perpendicular ASC 0.5

Vertical ASC 1
[a] ASC = Anisotropic Strain Coefficient

Machine Settings
Machine settings refer to process parameters for your AM machine setup. Inputs for machine settings
are used to calculate the real, physical time duration of the build process so that the cooldown time
can be determined. Every simulation except a simple isotropic strain simulation uses some, or all, of
the parameters shown in blue in the following figure and defined below.

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Input Parameter Definition

Start Layer Angle The orientation of fill rasters on the first layer of the part. It is measured
from the X axis, such that 0 degrees results in scan lines parallel to the X
axis. The starting layer angle is commonly set to 57 degrees. Must be
between 0 and 180°.
Layer Rotation Angle The angle at which the major scan vector orientation changes from layer
to layer. It is commonly 67 degrees. Must be between 0 and 180°.
Scan Stripe Width When using the stripe pattern for scan strategy, the geometry can be
broken up into sections, called stripes. The stripes are scanned sequentially
to break up what would otherwise be very long continuous scan vectors.
Slicing Stripe Width is commonly set to 10 mm wide. Must be between 1
and 100 mm.
Hatch Spacing The average distance between adjacent scan vectors when rastering back
and forth with the laser. Hatch spacing should allow for a slight overlap
of scan vector tracks such that some of the material re-melts to ensure full
coverage of solid material. For Machine Learning strain definition, must be
between 60 and 1000 microns.
Deposition Thickness The thickness of added powder material in every pass of the recoater blade.
Specifically, use the amount the base plate drops between layers. For
Thermal Strain strain definition, must be between 10 and 100 microns.
Scan Speed The average speed at which the laser spot moves across the powder bed
along a scan vector to melt material, excluding jump speeds and ramp up
and down speeds. For Thermal Strain strain definition, must be between
350 and 2500 mm/sec and the recommended range is between 500 and
2500 mm/sec.

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 Define Build Settings

Input Parameter Definition

Beam Power The power setting for the laser in the machine. Must be between 50 and
700 Watts. The recommended range is between 50 and 500 Watts.
Beam Diameter The width of the laser on the powder or substrate surface defined using
the D4σ beam diameter definition. Usually this value is provided by the
machine manufacturer. Sometimes called laser spot diameter. Must be
between 20 and 140 µm. The recommended range is between 80 and 120
µm.

• If Inherent Strain = Yes (default if AM Inherent Strain custom system is used):

– Scan Pattern Definition (visible if Inherent Strain Definition = Scan Pattern or Thermal Strain):
How the scan pattern is defined, either generated using a rotating stripe pattern (default) or
input via a build file.

→ Generated: Start Layer Angle and Layer Rotation Angle as defined above. Scan Stripe
Width is also visible if Inherent Strain Definition = Thermal Strain. These inputs define
an internally generated scan pattern.

→ Build File: Machine Type and Build File Path inputs become available with this option.
These inputs specify an external build file to be used.

• Machine Type: Specifies the machine or OEM associated with the build file spe-
cified. Options are Additive Industries, EOS, HB3D, Renishaw, Sisma, SLM, and
Trumpf.

• Build File Path: Location of a .zip file containing the scan pattern file(s), and an
stl of the part geometry. See Build File Requirements (p. 59).

– Beam Diameter, Beam Power, Deposition Thickness, Hatch Spacing, and Scan Speed as defined
above. If a build file is specified for Scan Pattern Definition, deposition thickness is determined
from the file.

• If Inherent Strain = No (default unless AM Inherent Strain custom system is used):

– Hatch Spacing, Deposition Thickness, and Scan Speed as defined above.

– Dwell Time: The span of time from the end of the laser scan of one layer to the start of the
laser scan of the next layer. It includes the time required for recoater-blade repositioning and
powder-layer spreading.

– Dwell Time Multiplier: The dwell-time multiplier accounts for more than one part in the build.
If they are the same part arranged in the same orientation on the build plate, the multiplier
is the number of parts.

– Number of Heat Sources: For multiple-beam printers, specifies the number of lasers. This divides
the amount of time it takes to scan a layer by the number of heat sources specified.

Build Conditions
Build conditions are the settings pertaining to the environment in the build chamber around the part
as it is being printed, including the preheat temperature. For Inherent Strain = Yes, only preheat

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Workflow Through the Project Tree

temperature is required and only with Inherent Strain Definition = Thermal Strain. For Inherent Strain
= No, additional inputs are required to account for convection.

During a laser powder bed fusion (LPBF) print process, almost all the heat dissipation is conducted
through the part back to the build plate rather than out through the unmelted powder surrounding
the part. Many users ignore the small effect of heat loss through powder but you may choose to model
it as equivalent heat convection.

The Gas/Powder Temperature option allows the use of Preheat Temperature for Gas Temperature and
Powder Temperature.

Input Parameter Definition

Preheat Temperature The starting temperature of the build plate. Used when Inherent Strain =
Yes and Inherent Strain Definition = Thermal Strain, and when Inherent
Strain = No. For Thermal Strain strain definition, must be between 20 and
500 °C and the recommended range is between 20 and 200 °C.
Gas Temperature Temperature of the gas in the build enclosure.
Gas Convection Coefficient Convection coefficient from the part to the enclosure gas. The convection
is applied only to the top of a newly laid layer.
Powder Temperature Temperature of the newly added powder.
Powder Convection Coeffi- Effective convection coefficient from the sides of the part to the powder
cient bed. To estimate, divide the conduction property of the powder by a
characteristic conduction length into the powder (for example, a quarter
of the distance from the part boundary to the build-chamber wall).
Powder Property Factor A knockdown factor used to estimate the powder properties. The
Mechanical application applies the factor to the solid material properties
to estimate the properties of the material in its powder state. The
powder-state properties are used in the newly added layer during the
heating of the new layer (before its subsequent solidification and cooldown)
prior to the next layer being applied. The default value is 0.01.

This powder knockdown factor is also used if powder is explicitly

modeled (p. 112) in the build.

Cooldown Conditions
Cooldown conditions are the settings pertaining to the environment in the build chamber around the
part in the cooldown step after the last layer is printed. Available only if Inherent Strain = No.

• Room Temperature

• Gas Temperature, Gas Convection Coefficient, Powder Temperature, and Powder Convection
Coefficient as defined above, with an option to use Room Temperature for Gas Temperature and
Powder Temperature.

Procedural Steps
You can go back to Workbench and select the Engineering Data tab at any time to see properties for
your chosen material.

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 Define Build Settings

1. Select the Build Settings object (under AM Process object).

2. In Details, enter values for all the items under Simulation Settings, Calibration Settings, Machine
Settings, Build Conditions, and Cooldown Conditions. You can load a pre-saved file of build settings
if you have one – right-click Build Settings and select Load Build Settings. (We provide generic
sample files for our AM materials in the ANSYS Inc directory, for example: C:\Program Files\ANSYS
Inc\v231\aisol\DesignSpace\DSPages\SampleData\AdditiveManufacturing. In this example, v231 in-
dicates Release 2023 R1. Note that the ANSYS Inc directory on your machine may not be on the C
drive.)

3. Right-click the Build Settings object and select Save Build Settings to save your inputs to an .xml
file that can be reused.

Build File Requirements

Listed here are the general requirements for build files, which are the same as those required for Additive
Print. Additional machine-specific requirements are provided in the expandable topics below the gen-
eral requirements.

• We define a build file as a .zip file containing, at a minimum: one .stl file for the part geometry
and one machine-specific print file defining the scan vectors. Supported machine manufacturers
include Additive Industries, EOS, HB3D, Renishaw, Sisma, SLM, and Trumpf. Ansys may add addi-
tional options as we continue to work with more machine partners.

• Build files from Additive Prep are automatically created with a file name of "ansys_addit-
ive_print.zip.

• The build file is a .zip file. Do not nest the files to be zipped within a folder, as a folder structure
is not readable. Rather, zip the individual files together as shown in the following figure.

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General requirements for the part geometry stl file

• Stl files within the .zip file must have units of mm and be positioned in the same location as the
part in Mechanical.

• Multiple parts can be used, but they must all be within one stl file.

• The baseplate should not be included in the part geometry stl file.

• Supports should not be included in the part geometry stl file nor as a separate stl file.

General requirements for the machine file

• One laser head is assumed for the simulation. Build files with multiple lasers are not supported. When
you import a build file with multiple lasers, the application handles it differently depending on the
machine. In most cases, the application either generates an error or ignores the extra lasers upon
import.

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 Define Build Settings

• One set of process parameters is used in the simulation. If the build file contains multiple parameter
sets, such as different scan speeds and laser powers for the part hatches versus the support hatches,
the part hatch parameters will take precedence.

• Only one part layer thickness (Deposition Thickness) is allowed.

• Only one support layer thickness is allowed, and it must be equal to, or a multiple of, the part layer
thickness.

• Regardless of how they are defined in the build file, the scan sequence is always simulated from the
inside out, that is, from hatch to contour scans. However, the appropriate order is maintained within
the hatch area and within a contour. For example, if the build file order is: contour line 1 → contour
line 2 → hatch line 1 → hatch line 2, it will be changed to be hatch line 1 → hatch line 2 → contour
line 1 → contour line 2.

• Scan vectors marked as contour will not be simulated. The definition of contour/hatch is established
by the software that creates the build file. If contour-like scan vectors are marked as hatch they will
be simulated and results may not be as expected.

• Build files for simulations that use the Machine Learning Prediction strain definition only support
stripe scan patterns.

Additive Industries Build Files

A build file for an Additive Industries machine should be a zip file containing:

• Part = *.stl file

• Two machine files are required, one *.daij file and one *.bin file.

Notes:

• Support scan vectors will be ignored and will not be simulated. An Additive Industries build file
with supports has not been tested.

• Only a stripe scan pattern has been tested.

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EOS Build Files

A build file for an EOS machine should be a zip file containing:

• Part = *.stl file

• Machine = *.openjz file. Workbench Additive uses version 2.8 of the EOS API.

Notes:

• You must have an EOSPRINT 2 license, in the form of a dongle or from a license server, from EOS in
order to import an EOS build file.. If you are using a dongle, do not unplug it until the after strains
have been generated.

• EOS M100, M290 and M400 single-laser machines are supported.

Known Issues and Limitations

• When preparing the .openjz file in EOSPRINT, start height and end height (<height> element)
should not be zero since it is never the position of any layer. The build file may fail to generate
strains in Mechanical.

• When attempting to import an older EOS build file, the application may reject it since version
2.8 of the EOS API is stricter in regards to the OpenJob format. If this happens, you may see an
error.

HB3D Build Files

A build file for an HB3D machine should be a zip file containing:

• Part = *.stl file

• Machine = *.h3d file. Workbench Additive uses version 1.0 of the *.h3d file specification.

Notes:

• An HB3D build file ignores the last layer when the distance from its Z coordinate to the Z max
is less than one layer thickness.

Renishaw Build Files

A build file for a Renishaw machine should be a zip file containing:

• Part = *.stl file

• Machine = *.mtt file. Workbench Additive uses version 1.06 of the *.mtt file specification.

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 Establish Thermal Analysis Settings (Thermal-Structural System)

Sisma Build Files

A build file for a Sisma machine should be a zip file containing:

• Part = *.stl file

• Machine = *.wza file. Workbench Additive uses version 3.0.9 of the *.wza file specification.

SLM Build Files

A build file for an SLM Solutions machine should be a zip file containing:

• Part = *.stl file

• Machine = *.slm file. Workbench Additive uses version 1.10 of the *.slm file specification.

Trumpf Build Files

A build file for an Trumpf machine should be a zip file containing:

• Part = *.stl file

• Machine = *.wza file. Workbench Additive uses version 3.0.9 of the *.wza file specification.

5.11. Establish Thermal Analysis Settings (Thermal-Structural System)

Go directly to procedural steps. (p. 64)

This step requires you to think about your simulation's end goals. What do you want to investigate?
And specifically, what data do you want to see from the transient thermal portion of an LPBF Thermal-
Structural simulation? Thermal analysis settings enable the customization of various options during the
transient thermal solution, including identifying which items to solve for.

The transient thermal analysis will determine the temperature history during the build process. These
temperatures will then be used in a static structural analysis to determine the build distortions and
stresses. The Mechanical application will automatically determine all the steps and times needed for
time integration in the simulation.

Options to consider include:

• Hotspot (p. 64) – A significant cause of issues in additive manufacturing can be attributed to
overheating during the build. This commonly occurs when there are changes in cross sectional
area and there is not enough material to pull heat away from a certain region. Overheating can
lead to poorly shaped melt pools that can affect material properties and porosity in the part.
You can check for the overheating issue with simulation by checking the temperature that each
layer cools down to before a new layer is added. Add an LPBF Hotspot result item to your project
so that the appropriate data is written out during solution. The LPBF Hotspot result tool sets the

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Export Layer End Temperature option so that the temperature of a layer just before a new layer
is applied is written out to a file.

• Layers to Build (p. 64) – An option is available to limit the number of layers to build in the
simulation, that is, to simulate only a partial build process. This may be useful if you want to
examine results in the lower portion of the build if you suspect there will be cracks or blade in-
terference there.

• Other Output Controls (p. 64) – For an AM Process Simulation, your results file will grow in size
very quickly, so we recommend you keep the default output control settings that will suppress
calculation of thermal flux, nodal forces, Euler angles, volume and energy, and other miscellaneous
items. Nodal temperatures are stored at all time points by default but you can change that option
so that temperatures are stored at the last heating and cooling steps only, or every N number
of finite element layers.

Procedural Steps
Usually it is appropriate to leave most analysis settings set to "program-controlled." These settings are
determined when you insert the AM Process object into the project tree. There are a couple of settings
to note related to an AM Process Simulation, as described below.

1. To solve for hotspots, use the LPBF Hotspot tool in the LPBF Process Add-on.

Load the LPBF Process Add-on (p. 8) if you have not already done so. From the LPBF Process tab,
click the LPBF Hotspot button. A new result object, called AM Hotspot, is added in the project tree
under Solution in the Transient Thermal environment. (Alternatively, you can right-click Solution
and select Insert > AM Hotspot.)

The LPBF Hotspot result tool automatically sets the Export Layer End Temperature option to Yes in
the Analysis Settings object under Output Controls. It will write out to a file the temperature of a
layer just before a new layer is applied. Node numbers and x, y, z locations are also written. The
output is not written to the results file but rather to a tab-delimited file called AMResults.txt.

2. If you want to limit the number of layers to build in the simulation, select the Analysis Settings
object under the Transient Thermal object and in Details, Additive Manufacturing Controls, change
the Layers to Build to your desired value. Your results file will show results from the beginning
layer only through the specified layer. (Hint: If you change the value of Layers to Build and you want
to set it back to All, enter 0.) Pay attention to the active step as indicated at the top of the Details
panel under Step Controls. The number of Layers to Build in the Cooldown Step will always equal
the number of Layers to Build in the Build Step.

3. In Details of Analysis Settings, review the Output Controls and adjust them according to your
needs.

• To change the option of when to store element results for the Build Step, select Store Results
At and choose All Time Points, Last Heating and Cooling Steps, or Every N Layers. (Layers
refers to finite element layers, not powder deposition layers.)

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 Apply Thermal Boundary Conditions (Thermal-Structural System)

5.12. Apply Thermal Boundary Conditions (Thermal-Structural System)

In the Build Settings step of our workflow, we have already accounted for convection between the build
and the gas in the chamber and convection between the build and the unmelted powder around the
part—in both the Build Step and the Cooldown Step. There is one other area of heat transfer to consider
and that is associated with the base plate.

During the build process, the plate is typically heated on the bottom to maintain a constant, slightly
elevated temperature. You may insert a temperature constraint or convection surface to simulate this
during the build step. If the plate is not heated, perhaps apply a room condition convection surface,
or set the surface boundary condition to adiabatic.

After the print process is complete, the base plate heating is removed and the built part cools to room
temperature. This is simulated by a room-temperature convection surface applied to the bottom of the
base plate in the cooldown step.

The time duration of the cooldown step is estimated based on the average part temperature at the
end of the build, its volume, and material properties. Using the convection values and room temperature,
the Mechanical application solves the simple heat transfer equation to get an estimate of the cool down
time. It is only an estimate so you can extend it if required or put in a preferred time in analysis settings.
One final step is performed to force all the temperatures to room temperature for the subsequent dis-
tortion and stress calculation.

Procedural Steps
To apply a temperature to the bottom surface of the base plate for the build step:

1. Right-click the Transient Thermal object and then select Insert > Temperature.

2. Select the bottom surface of the base plate (geometry selection) and hit Apply in the Details view.

3. In Details under Definition, Temperature, enter a temperature value for Magnitude. (In our example
we use 80°.)

4. In the Tabular Data area of the interface, notice the temperature value you just entered is applied
for all sequence steps. (The first row of tabular data is considered T=0, the preheat condition.) In
the printing process, since the heat is removed after the part is printed, you'll need to remove the
temperature boundary condition for the cooldown step of the simulation. Right-click in the third
row and click Activate/Deactivate at this step! which will deactivate (remove) the elevated temper-
ature for the cooldown step.

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To apply room-temperature convection to the bottom surface of the base plate for the cooldown step:

1. Right-click the Transient Thermal object and then select Insert > Convection.

2. Select the bottom surface of the base plate (geometry selection) and hit Apply in the Details view.

3. In Details under Definition, Film Coefficient, enter a value for the convection coefficient.

4. Under Ambient Temperature, enter a value of 22°. (This may be the default.)

5. In the Tabular Data area of the interface, select the first two rows, right-click and select Activate/De-
activate at this step! which will deactivate (remove) the convection for the build step.

5.13. Solve the Transient Thermal Analysis (Thermal-Structural System)

Some users prefer to solve the thermal analysis first to observe how the simulation is progressing while
others prefer to set up everything and run both the thermal and structural analyses at once. Either way
is perfectly acceptable. To run them both at once, simply execute a solve from the static structural side
and the transient thermal analysis will be run first automatically.

Since the solution can take significant time to complete, a solution status window is provided that in-
dicates the overall progress of the solution. Other solution trackers and tools allow you to i) view the
actual output from the solver, ii) graphically monitor items such as convergence criteria, and iii) view

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 Establish Structural Analysis Settings

the temperature contour as the build progresses. You can also monitor some result items such as
temperature at a node as the solution progresses.

Procedural Steps
1. To set up a plot of overall temperature that you can update throughout the solution, under Transient
Thermal, Solution, Solution Information, select Insert > Temperature Plot Tracker.

2. To initiate the solution, under Transient Thermal, highlight the Solution object, right-click and select
Solve.

3. Use the temperature plot tracker occasionally or continuously, as follows:

• Whenever you want to see the updated temperature, right-click the Temperature plot
tracker object and select Update Result. Or,

• Right-click the Temperature plot tracker object and select Switch to Automatic Mode. This
will show a continuous, live display as the solution progresses. The plot tracker object must
be selected in order to see the live display.

5.14. Establish Structural Analysis Settings

Go directly to procedural steps. (p. 68)

In this step, think about your end goals for the simulation and what data you want to see written out
from the structural portion of the simulation. Structural analysis settings allow for the customization of
various options during the static structural solution, including identifying which items to solve for.

Options to consider include:

• Recoater Interference (p. 68) – A significant concern in additive manufacturing is whether the
build will print successfully without experiencing recoater interference (sometimes called blade
crash). This phenomenon occurs when the powder recoater blade hits into a portion of the built
part that has deformed extensively because of residual stresses. Usually the result is a stopped
process and a failed build. If checking for recoater interference is a simulation goal, add an LPBF
Recoater Interference result now to your project so that the appropriate data is written out
during solution. The LPBF Recoater Interference result tool configures the Export Recoater Inter-
ference output control option so that the z-deformation of a layer just before applying a new
layer is written out to a file.

• High Strain (p. 68) – When the strain in a part exceeds the elongation a material can withstand,
a failure can occur resulting in cracking throughout the part or supports. The LPBF High Strain
result tool allows you to identify regions of the part that may be prone to forming cracks during
or after the build process by highlighting critical strain values. The LPBF High Strain result tool
configures the Export High Strain output control option so that the maximum equivalent strain
experienced during the build process is written out to a file.

• Reference Temperature (p. 69) – The Reference Temperature is the temperature at which
thermal strains do not exist in a material. In the simulation of the AM process, our assumption
is that each finite element super layer is added (with the element birth/death technique) at the
melting temperature for the material and is initially strain-free. (We set Tref = Tmelt by default.)
As the build cools, thermal strains develop. The static structural analysis will use the temperature

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Workflow Through the Project Tree

results of the transient thermal analysis to compute the displacements, stresses, strains, and
forces due to these induced thermal strains.

• Relaxation Temperature (p. 69) – If you will be simulating a heat treatment process such as
annealing after the build, you will probably want to specify a Relaxation Temperature. Lower
than the melting temperature, the relaxation temperature is the temperature at which strains
begin to soften. (Using a creep model in Engineering Data is an alternative stress relaxation
mechanism.) Refer to the advanced topic Simulating Heat Treatment after the Build (p. 100) for
details.

• Layers to Build (p. 69) – An option is available to limit the number of layers to build in the
simulation, that is, to simulate only a partial build process. This may be useful if you want to
examine results in the lower portion of the build if you suspect there will be cracks or blade in-
terference there. The number specified here must not be more than the number of layers to
build used in the thermal analysis step if you are performing a thermal-structural simulation.

• Other Output Controls (p. 69) – Your structural results file will grow in size very quickly, so we
recommend you keep the default output control settings that will suppress calculation of contact
data, nodal forces, Euler angles, volume and energy, and other miscellaneous items. Consider
suppressing the calculation of stresses and strains if you are only interested in distortion, as
these data, in particular, will easily increase the size of the results file and it may become unman-
ageable. Additional controls allow you to specify when to store results for the build step: for all
layers, for the last heating and cooling steps, or every N layers.

Procedural Steps
As with the thermal analysis, many analysis settings in the structural analysis are program controlled.

1. To solve for recoater interference, use the LPBF Recoater Interference tool in the LPBF Process Add-
on.

Load the LPBF Process Add-on (p. 8) if you have not already done so. From the LPBF Process tab,
click the LPBF Recoater Interference button. A new result object, called LPBF Recoater Interference,
is added in the project tree under Solution in the Static Structural environment. (Alternatively, you
can right-click Solution and select Insert > LPBF Recoater Interference.)

The LPBF Recoater Interference result tool automatically sets the Export Recoater Interference option
to Yes in the Analysis Settings object under Output Controls. It will write out to a file the z-deform-
ation of a layer just before a new layer is applied. Node numbers and x, y, z locations are also written.
The output is not written to the results file but rather to a tab-delimited file called AMResults.txt.

2. To solve for high strain areas, use the LPBF High Strain tool in the LPBF Process Add-on.

Load the LPBF Process Add-on (p. 8) if you have not already done so. From the LPBF Process tab,
click the LPBF High Strain button. A new result object, called LPBF High Strain, is added in the
project tree under Solution in the Static Structural environment. (Alternatively, you can right-click
Solution and select Insert > LPBF High Strain.)

The LPBF High Strain result tool automatically sets the Export High Strain option to Yes in the Ana-
lysis Settings object under Output Controls. It will write out to a file the maximum equivalent strain
experienced during the build process. Node numbers and x, y, z locations are also written. The
output is not written to the results file but rather to a tab-delimited file called AMHighStrain.txt.

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 Apply Structural Boundary Conditions

3. Select the Analysis Settings object under the Static Structural object and in Details, note the Ad-
ditive Manufacturing Controls. The Reference Temperature is automatically set to the material's
melting temperature. (You can see this value in Engineering Data for your chosen material.)

4. If you added a Heat Treatment Step in the AM Process Sequencer, you will probably want to specify
a Relaxation Temperature. Under Additive Manufacturing Controls, change the Relaxation Temper-
ature to User Specified and change the Value to the appropriate temperature. See the advanced
topic Simulating Heat Treatment after the Build (p. 100) for additional steps to complete the Heat
Treatment Step.

5. To limit the number of layers to build in the simulation, under Additive Manufacturing Controls
change the Layers to Build to your desired value. The number specified must not be more than
the number of layers to build used in the thermal analysis if you are performing a thermal-structural
simulation.

6. Review the Output Controls and suppress items not of interest.

• Turn off calculations of Stress and Strain by changing those options from Yes to No. (Hint:
Simply double-clicking in the Yes box changes it to No.)

• To change the option of when to store results, select Store Results At and choose All Layers,
Last Heating and Cooling Steps, or Every N Layers.

5.15. Apply Structural Boundary Conditions

Unless you specified a base removal step, the only boundary condition that must be applied is a fixed
support boundary condition on the build plate. If a base removal step is included, you need to apply
fixed boundary conditions on three nodes of the part to prevent rigid body motion when the base is
removed.

Procedural Steps
Under the Static Structural object, notice there is already an Imported Load object. This is the result of
the linked analysis system and represents the temperature results from the transient thermal solution.

1. To fix the bottom surface of the base plate, right-click the Static Structural object and then select
Insert > Fixed Support. Select the bottom surface of the base plate (geometry selection) and hit
Apply in the Details view. If you have a more detailed geometry for the base, such as one with bolt
holes that you want to explicitly simulate, apply the boundary conditions to affix the plate accordingly.

2. If you specified a base removal step, you'll need to constrain the part at three nodes to prevent rigid
body motion. Be aware that you will be constraining the nodes to their displaced position at the end
of the build, rather than constraining them to 0. (For example, if the node displaced 0.1 mm during
the simulation, the constraint will keep the node at 0.1 mm.) Use a Commands object to do this.

a. You may want to hide the base body during this process. Right-click the base body and select
Hide Body.

b. Zoom in to the area of the part where you will apply constraints. Switch to Node mode of selec-
tion.

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c. Create nodal named selections: Right-click Model in the project tree, and select Insert > Named
Selection. Select a node on the bottom of the part, perhaps toward the middle of the part. You
should choose nodes that are unimportant to your results. Perhaps spread them out over the
bottom of the part but the nodes must not be co-linear. Your node selection will affect displacement
results but not stresses or strains. Click Apply in Details. Right-click the newly created Selection
in the project tree (under Named Selections) and select Rename. Name it to something short
and descriptive, such as CN1 (for constrained node 1). Do the same step two more times and
rename them to CN2 and CN3.

d. Create commands to constrain the nodes: Click the Static Structural object and select Commands

from the context menu. Or, right-click and select Insert > Commands. In the Commands
window that is displayed, copy and paste, or type, the following:
D,CN1,UX,%_FIX%
D,CN1,UY,%_FIX%
D,CN1,UZ,%_FIX%
D,CN2,UY,%_FIX%
D,CN2,UZ,%_FIX%
D,CN3,UZ,%_FIX%

Constrained node 1 is fixed in UX, UY, and UZ and holds the part in place. Constrained node 2
is fixed in UY and UZ, and constrained node 3 is fixed in UZ; these prevent rotation. Selection
of CN1 can have a big effect on the displacement throughout the part. See the D command,
which defines degree-of-freedom constraints at nodes, for more information.

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 Solve the Static Structural Analysis

e. Match the commands to the base removal sequence step: Select the newly created Commands
object under Static Structural and, in Details, change the Step Selection Mode to By Identifier.
Change the Step Number to Removal Step: Base. This ensures the constraints are applied just
before the base removal step.

f. Remember to make the base plate visible again if you hid the body. Right-click the base body
and select Show Body.

5.16. Solve the Static Structural Analysis

You initiate the structural solution in this step. Watch convergence plots or a live tracker of the total
deformation as the solution progresses.

Procedural Steps
1. To set up a plot of overall deformation that you can update throughout the solution, under the
Static Structural object, Solution Information, select Insert > Deformation Plot Tracker.

2. To initiate the solution, under Static Structural, highlight the Solution object, right-click and select
Solve.

3. Use the deformation plot tracker occasionally or continuously, as follows:

• Whenever you want to see the updated deformation, right-click the Total Deformation plot
tracker object and select Update Result. Or,

• Right-click the Total Deformation plot tracker object and select Switch to Automatic Mode.
This will show a continuous, live display as the solution progresses. The plot tracker object
must be selected in order to see the live display.

4. To observe convergence plots during solution, click Solution Information and in the Details panel,
under Solution Output, choose from among the selections in the drop-down list, such as Force
Convergence.

Restarts
Multiframe restarts for additive manufacturing analyses can be set up for any AM step specified by the
AMSTEP command. Restarting and continuing a partially complete build step by issuing another AM-

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Workflow Through the Project Tree

STEP,BUILD command is not enabled at this time. Restarts with additive manufacturing otherwise follow
the capabilities outlined here.

5.17. Review Results

For any simulation in Mechanical, once a solution is available you can view a contour plot or animate
the results (p. 74). There are solutions at many time points in a transient analysis and you can display
the variation of a result item at a location over time. So for a LPBF Thermal-Structural simulation you
can view a result at a location on the build over the build history.

In addition to those general results, the following are result items of particular concern for AM simulations:

• Recoater Interference (p. 75) – The LPBF Recoater Interference result tool allows you to identify
excessive deformation in the Z direction that may lead to interference with the powder spreading
mechanism during printing.

• High Strain (p. 77) – The LPBF High Strain result tool allows you to identify regions of the part
that may be prone to forming cracks during or after the build process by highlighting critical
strain values.

• Hotspot (p. 78) – The LPBF Hotspot result tool is used to identify areas of overheating that may
result in problematic thermal conditions. This result is available for thermal-structural simulations
only.

• Deformation Along a Line (p. 79) – At times you may want to obtain results along an edge or
other specific location of the part to determine if the part will be within tolerances or to compare
to distortion measurements made after the part is built. This technique is used when calibrating
Strain Scaling Factors (p. 118), for instance. There are several ways to obtain this result.

• 3D Printing Time Estimate (p. 80) – Get an estimate of the real 3D printing time.

Procedural Steps
Recall that you used Output Controls under Analysis Options and/or AM-specific result items to control
which items are solved for in the simulation. Perhaps you set up results trackers in the solution step to
observe the results being processed during the solution. When reviewing results after the solution, you
will generally need to evaluate results to obtain them for viewing. Evaluating results is a way to retrieve
them from the data that was stored during solution. Only data items that were solved for may be re-
trieved in this way.

There are many different ways to view results but some of the ones most commonly used for additive
manufacturing are described here:

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 Review Results

Animate Thermal Results - Temperatures (Thermal-Structural System)

1. In the project tree under Transient Thermal, select the Solution object and then, in the context
menu, click Thermal and then Temperature. Or right-click Insert > Thermal > Temperature.
A Temperature object is created and becomes active.

2. Right-click Temperature and select Evaluate All Results. This retrieves the temperature data
and displays it in both graph and tabular form.

3. Use the animation controls at the top of the Graph window. Click the Result Sets button

and also the Update Contour Range at Each Animation Frame button . Adjust the
number of seconds for the animation and click Play. See Animation in the Mechanical User's
Guide for more information about animation controls.

The following is an animated GIF. Refresh the page to see the animation. View online if you are
reading the PDF version of the help.

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Animate Structural Results - Total Deformation

1. In the project tree under Static Structural, select the Solution object and then, in the context
menu, click Deformation and then Total. A Total Deformation object is created and becomes
active.

2. Right-click Total Deformation and select Evaluate All Results. This retrieves the deformation
data and displays it in both graph and tabular form.

3. Use the animation controls at the top of the Graph window.

4. It is important (and fun!) to change the magnification scale of the display in the Geometry
window so you can get a true sense (or an exaggerated sense) of the deformation in your
build. With Total Deformation highlighted in the project tree, from the Result context tab,
select the True Scale option from the drop-down menu. Animate the results using the animation
controls. Select other scales from the drop-down menu to see exaggerated results.

The following is an animated GIF. Refresh the page to see the animation. View online if you are
reading the PDF version of the help.

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 Review Results

Check for Recoater Interference

You need to define some sort of threshold for the level of Z-deformation that is considered to be
recoater interference. In the LPBF Recoater Interference Details view, change the Threshold
Definition to one of these three options:

• None - The result tool will show pure Z-deformation in the build, where the value at each
point corresponds to the Z-deformation when that material was a new layer.

• Layer Thickness Based (default) - The result tool uses the Deposition Thickness (set in the
Build Settings object) and a new input field, Powder Packing Density, to determine the
thresholds for warning and critical deformation. Specifically, if the Z-deformation for any
layer is equal to or greater than the Deposition Thickness it is considered a warning. If the
Z-deformation is equal to or exceeds the ratio of Deposition Thickness/Powder Packing
Density it is considered critical. Powder Packing Density may be dependent on the powder
particle size, material, spreading mechanism, or other factors.

• User Defined - You define your own warning and critical thresholds.

Once you have chosen your Threshold Definition, right-click the LPBF Recoater Interference
object and select Evaluate All Results. The resulting display shows the model with color contours
based on the threshold criteria you selected. For the Layer Thickness Based and User Defined op-
tions, contours are shown as follows:

• 0 = Safe

• Between 1 and 2 = Warning

• 2 and above = Critical

Important:

The data displayed is based on the Z deformation of each layer right before the next layer
is added. It does not represent the "final state" of deformation at the end of the cool-
down step.

Note:

To ensure a quick, dynamic calculation of results, Calculate Time History is set to No

by default for this result item. Set Calculate Time History to Yes and then right-click
on Evaluate All Results to see the time history results, such as the layer-by-layer anim-
ated build. For large models, the calculation may take some time.

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Workflow Through the Project Tree

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 Review Results

Check for High Strain Areas

The LPBF High Strain result shows the maximum equivalent strain experienced during the build
process. It can help to identify regions at risk of cracking.

Just as you do for the recoater interference result, consider defining a threshold for the level of
strain that is considered to be of concern for your material. In the LPBF High Strain Details view,
set the Threshold Definition to one of these options:

• None (default) - The result tool will show pure maximum equivalent strain in the build,
where the value at each point corresponds to the strain when that material was a new
layer.

• User Defined - You define your own warning and critical thresholds.

Once you have chosen your Threshold Definition, right-click the LPBF High Strain object and
select Evaluate All Results. The resulting display shows the model with color contours based on
the threshold criteria you selected. For the User Defined option, contours are shown as follows:

• 0 = Safe

• Between 1 and 2 = Warning

• 2 and above = Critical

Note:

To ensure a quick, dynamic calculation of results, Calculate Time History is set to No

by default for this result item. Set Calculate Time History to Yes and then right-click
on Evaluate All Results to see the time history results, such as the layer-by-layer anim-
ated build. For large models, the calculation may take some time.

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Workflow Through the Project Tree

Check for Hotspots (Thermal-Structural System)

The LPBF Hotspot result is applicable for the thermal portion of an LPBF Thermal-Structural simu-
lation. Use the result item after the thermal portion, at least, is solved.

Right-click the LPBF Hotspot object and select Evaluate All Results. The resulting display shows
the temperature of each layer right before the next layer is added. The worst hotspots are going
to be the areas with the highest temperature for that layer.

Read-only result data show the minimum and maximum temperature values and where they occur
(part or support).

Results are localized (based on nodal values), not averaged across the layer. Use a section plane
to reveal hotspots inside the part.

Important:

The data displayed is based on the temperature that the build cools down to at the end of
each layer right before the next layer is added. It does not represent the "final state" of
temperatures at the end of the cooldown step.

Note:

To ensure a quick, dynamic calculation of results, Calculate Time History is set to No

by default for this result item. Set Calculate Time History to Yes and then right-click
on Evaluate All Results to see the time history results, such as the layer-by-layer anim-
ated build. For large models, the calculation may take some time.

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 Review Results

Scope a Line of Nodes to Get Results at a Specific Location

Suppose you want to obtain X-direction deformation along a line on a face of your part, such as
shown below, at the end of the cooldown step.

There are several ways to perform this function but we will demonstrate it using a Worksheet. To
obtain distortion results along a line on the surface of your part:

1. Create a named selection: Highlight the Model object, right-click and select Insert > Named
Selection. Right-click the newly created Selection object (under Named Selections) and Rename
to something meaningful, for example, Line of Nodes.

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Workflow Through the Project Tree

Get an Estimate of the Actual 3D Printing Time

View the solver output to get an estimate of the real machine build time. It is approximately the
transient thermal build step simulation time multiplied by R^(1/3), where R is the number of de-
posit layers in one element layer. This data is available after the thermal solution. Click the Solution
Information object and then click the Worksheet tab under the Geometry window. In the Details
view, be sure that Solver Output is selected as Solution Output.

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Chapter 6: Advanced Topics
This chapter describes additional topics that you may want to consider for AM Process Simulations, in-
cluding the following:
6.1. Using Topology Optimization for Additive Manufacturing
6.2. Using the Inherent Strain Method
6.3. Using AM Octree Adaptive Meshing
6.4. Using Variable Layer Height
6.5. Understanding Machine Learning Thermal Strain
6.6. Performing a Directed Energy Deposition (DED) Process Simulation (Simplified Approach)
6.7. Simulating Heat Treatment after the Build
6.8. Capturing a Buckled Shape with Large Deflection
6.9. Modeling a Symmetrical Part
6.10. Modeling Powder with Elements
6.11. Modeling Clamps, Measuring Devices and Other "Non-Build" Components
6.12.Troubleshooting Convergence Issues

6.1. Using Topology Optimization for Additive Manufacturing

Topology optimization is an exciting technology that allows designers to optimize material layout
within a given design space, for a given set of loads, boundary conditions and constraints, with a goal
of maximizing the performance of a product. The optimal shape of a part is often organic and counter-
intuitive, and difficult or impossible to manufacture using traditional methods. By its very nature, additive
manufacturing opens up whole new possibilities for the real-world production of these optimized parts.
Along with the potential gains comes challenges unique to the manufacturing process, however. We've
seen that the use of supports for overhanging features during the printing process is necessary but
costly. If we could optimize our product designs while minimizing the requirement for supports at the
same time, we will be taking advantage of the best of both technologies.

The AM Overhang Constraint available in Ansys Mechanical's topology optimization tools allows us
to do just that. The goal of the overhang constraint is to create a self-supporting structure so that it may
be printed without adding supports. We will examine the overall workflow of using topology optimization
combined with AM Process Simulation as well as the specific usage of the overhang constraint in this
section. See Structural Optimization Analysis for a general discussion of how this technology is imple-
mented in Ansys Mechanical.

Topology Optimization and AM Process Simulation Workflow

The general workflow in a linked topology optimization and AM simulation is shown in the following
figure.

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Advanced Topics

Step A – Run an initial static structural analysis to establish loads and boundary conditions and baseline
results in Mechanical.

Step B – Run the topology optimization analysis with the AM Overhang Constraint in Mechanical.

• Highlight Topology Optimization, right-click and select Insert > AM Overhang Constraint. In Details,
change Build Direction and Overhang Angle to your desired values.

Parts designed using the AM Overhang Constraint are constrained more and results will include more
material than those optimized without the constraint. To allow more flexibility in solving this highly
nonlinear problem, we recommend you specify a range for the response constraint rather than just
a constant value. For example, if you want to reduce the mass in your part by 70%, we recommend
you allow the program to use a Percent to Retain range between 25 and 30% for maximum flexibility
in the algorithm. Defining a range for response constraint in combination with overhang constraint
will frequently require fewer iterations.

• Under Topology Optimization, select Response Constraint. In Details, under Definition, choose Mass
or Volume for Response. Change Define By to Range and enter a range of values for Percent to
Retain Min and Max.

Step C – Clean up the optimized geometry in SpaceClaim and then validate the design in Mechanical.
Search for the Additive Manufacturing section in the SpaceClaim documentation. Also, see Performing
Design Validation in the Mechanical User's Guide.

Steps D and E – Run the additive manufacturing simulation on the optimized design in Mechanical.

AM Overhang Constraint Methodology

The AM Overhang Constraint is defined by a printing direction and an overhang angle. The printing
direction can be one of the global coordinate system axes (either the positive or negative direction).

The overhang angle restricts the state of optimized elements. (Optimized elements are those that are
"kept" in the final design and that contribute to the system's overall stiffness matrix; that is, are filled
with material.) An element will be kept only if there is a supporting element in the layer below (or
above depending on the printing direction) that is also filled with material. An element is called a sup-

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 Using Topology Optimization for Additive Manufacturing

porting element of another element if the angle between the line defined by their centroids and the
base plate is greater than, or equal to, the overhang angle. The following figure demonstrates the re-
striction with an overhang angle of 45° in 2D. The printing direction is from the bottom to the top. In
order to fill the yellow element with material, at least one of the blue elements has to be filled, too.
Which of the blue elements will be kept depends on the state of the surrounding elements as well as
the load path. In the final design all remaining optimized elements have supporting elements.

Base Plate

The surface of the base plate is a plane perpendicular to the build direction. The base plate touches
the design region from below for positive printing direction (or from above for negative ones). For a
design to be printable, it requires a connection to the base plate. The results will depend on the size
of the area of contact. Results of the optimization will improve with increased contact area.

Excluded Elements

Excluded elements in the design region can lead to designs that do not satisfy the overhang constraint.
It cannot be guaranteed that these excluded elements are supported with respect to the overhang
angle. Excluded elements are always considered to provide support to optimized elements.

Example of AM Overhang Constraint Used in Topology Optimization

As shown in the following figure, a bracket-type component has two counterbored bolt holes at one
end and a through hole going through two flanges at the other. The bolt holes are fixed and a remote
force is applied to the two holes of the flanges. These regions are excluded from the topology optimiz-
ation and are shown in red. The remainder of the geometry is our design region (purple). We want to
minimize material on the component while still maintaining its ability to structurally support the loads.

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Advanced Topics

We used topology optimization first without, and then with, the AM Overhang Constraint. We set a
mass response constraint range of 10-13% material to retain. When using the AM Overhang Constraint,
we set an overhang angle of 45°. The print (or build) direction is from 0 along the positive Z axis.

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 Using Topology Optimization for Additive Manufacturing

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Advanced Topics

Comparing the two models, you can see there are several surfaces that will require supports in the first
image, especially underneath the branched structures. While not entirely eliminating them, the second
model minimizes these surfaces. Note also that the through holes will need to be supported during 3D
printing. The hole surfaces were not modified, as they were excluded regions.

6.2. Using the Inherent Strain Method

The Inherent Strain method provides an alternative to a coupled thermal-structural additive process
simulation available in Workbench Additive. With the Inherent Strain method, strains are calculated not
from material properties and thermal loads but from the use of a calibration factor, or Strain Scaling
Factor. The strain is equal to the Strain Scaling Factor multiplied by yield strength and divided by
elastic modulus:

The Strain Scaling Factor (SSF) is an important factor quantifying the variables unique to each build
scenario. It must be experimentally determined for each machine and material combination of interest.
We recommend you perform the same calibration procedure used for Ansys Additive, as described in
the Additive Print and Science Calibration Guide.

The SSF value is a direct multiplier to the predicted strain values. Using a value of 1 (default) will result
in strain magnitudes as calculated by the solver. Some material and geometry combinations result in
bulging/expansion rather than shrinkage and so a negative SSF is possible. Values between -1 and 1

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 Using the Inherent Strain Method

will reduce displacement and stress while values outside of that range will amplify them. Using a value
of 0 will result in no strain and the final displacement will match the input geometry.

You can define calibration factors that are different in each direction (X, Y, and Z) based on the Global
coordinate system by choosing Anisotropic Inherent Strain Definition. The properties of materials will
differ in different directions. If Inherent Strain Definition = Scan Pattern or Thermal Strain, individual
calibration factors, called anisotropic scaling coefficients (ASCs), may be entered based on the local
orientation of scan vectors within the part, that is, parallel and perpendicular to scanning direction and
in the build direction.

The steps in a typical additive manufacturing simulation are shown in the table below. Considerations
unique to using the Inherent Strain method are described.

Inherent Strain Workflow at a Glance

Simulation Step Considerations for Inherent Strain Method
1. Create analysis system Select the AM LPBF Inherent Strain custom system in Workbench.
2. Define engineering data Necessary only if you are using your own user-defined material.
(Ansys-supplied sample AM materials are automatically available
if you used AM LPBF Inherent Strain custom system.)
3. Attach geometry and launch No special considerations.
Mechanical
4. Identify geometry No special considerations.
5. Assign materials No special considerations.
6. Apply mesh controls and No special considerations, other than if you will be using AM octree
generate mesh adaptive meshing (p. 88), in which case Cartesian meshing with
voxelization option is required. Adaptive meshing is available only
with Inherent Strain simulations.
7. Identify and/or generate supports No special considerations.
8. Define connections No special considerations.
9. Define AM process steps Note there is no cooldown step.
10. Define build settings Set Inherent Strain = Yes (Automatic if you used AM LPBF Inherent
Strain custom system.)

Set Inherent Strain Definition to isotropic, anisotropic, scan

pattern, or thermal strain. The thermal strain definition uses
the machine learning (ML) method.

Define process parameters. Required inputs depend on the

selected strain definition.

Enter strain scaling factors, usually determined by a calibration

procedure.
11. Establish structural analysis Review and change output controls as needed. Most items are not
settings stored during solution to reduce result file size. Consider
suppressing the calculation of stresses and strains if you are
interested only in distortion.
12. Apply structural boundary Apply a fixed condition to the underside of the base assuming the
conditions base is rigid with no distortion.

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Advanced Topics

Inherent Strain Workflow at a Glance

Simulation Step Considerations for Inherent Strain Method
13. Solve the static structural No special considerations.
analysis
14. Review results No special considerations.

6.3. Using AM Octree Adaptive Meshing

For additive manufacturing Inherent Strain simulations, a special case of nonlinear mesh adaptivity is
available in which simulation time is reduced by coarsening elements in previously deposited layers,
thereby reducing the total number of elements. A simple 2D representation of mesh coarsening is
shown below, in which four square elements are combined into one larger square element.

The AM octree method was created specifically for use with laser powder bed fusion simulations, which
commonly use cubic (voxelized) elements. The octree method combines eight cubic elements into a
new, single cubic element, as shown in this 3D representation.

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 Using AM Octree Adaptive Meshing

Nonlinear mesh adaptivity modifies the mesh automatically during the solution based on specified cri-
teria. Mesh modifications occur by general remeshing with the AM octree technique. Loads, boundary
conditions, contact conditions, solutions variables, etc., are seamlessly transferred to the new mesh as
the solution progresses. Aside from setting the initial criteria, no user action is required.

AM octree adaptive meshing criteria include the designation of buffer regions, both vertical layers and
edge elements, to control where a fine mesh is maintained, along with layer frequency to modify how
often the program remeshes elements. The figure below shows four buffer layers and two buffer elements.

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Advanced Topics

The goal of AM octree adaptive meshing is to reduce simulation time. However, keep in mind that
remeshing takes time, so remeshing too frequently may not provide a simulation time benefit.

Procedural Steps
The AM octree method is a special case of nonlinear mesh adaptivity designed for mesh coarsening.
To use AM octree adaptive meshing:

1. Set up an AM LPBF Inherent Strain (p. 86) simulation in the usual way and be sure to use voxilized
meshing (p. 30) (Mesh Method with Method = “Cartesian” and Mesh Using Voxelization = “Yes”).

2. Apply a Nonlinear Adaptive Region. The Nonlinear Adaptive Region condition enables you to change
the mesh during the solution phase. It acts as a remesh controller based on certain criteria. The
criteria determine whether or not the mesh will be modified and, if so, which locations will be
modified.

On the Environment context tab: click Conditions > Nonlinear Adaptive Region. (Or, right-click
the Static Structural tree object, or anywhere in the geometry window, and select Insert > Nonlinear
Adaptive Region.)

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 Using AM Octree Adaptive Meshing

3. Set remesh criteria:

• Scoping will always read All Build Bodies if AM Process is in the project tree, however the
AM Octree method is currently limited to a single body with one support, and the support
will not be considered for mesh coarsening. Similarly, the base plate is not taken into account.

• Criterion: This is set to AM Octree automatically if AM Process is in the project tree.

• Remesh Layer Frequency: Frequency with which the program will perform remeshing. A
value of 10 will remesh every 10 layers throughout the AM build.

• Buffer Layers: Number of layers to keep at fine mesh resolution between the current, top
layer and the layers to be remeshed. Defaults to 2.

• Buffer Elements: Number of buffer elements to keep at fine mesh resolution between the
part edges and the remeshed elements. Defaults to 2.

For both buffer inputs, higher values may ensure better accuracy, but reduces the number of elements
that can be coarsened.

4. Solve the simulation.

5. View the coarsened mesh by selecting a result item and then using a section plane to see inside
the part. Hint: The best way to see the effect of remeshing is to make a clean, vertical slice through
the model.

6. View the time steps at which remeshing took place by looking for Changed Mesh = Yes in tabular
data when a result item or Solution is selected.

Notes on Usage and Known Limitations

Following are considerations and limitations when using AM octree adaptive meshing:

• AM octree adaptive meshing is available only for LPBF Inherent Strain simulations. (Because the
octree technique is used in the structural solver, it is not available for the thermal portion of a
thermal-structural simulation or even the structural step of a thermal-structural simulation where
temperature mapping is based on a consistent mesh between the thermal and structural analyses.)

• AM octree adaptive meshing is available only with a voxelized mesh (Cartesian mesh with
voxelization option (p. 34)).

• Setup for the AM octree method is currently limited to a single body with one support. Models
with multiple build bodies that are effectively touching might not be remeshed independently,
resulting in errors.

• Cubic elements that comprise the part are considered eligible for remeshing. The support, the
base plate, and any other non-cubic elements are not taken into account.

• Cubic elements with a knockdown factor less than 1, such as those found around edges or in
narrow areas that are not completely dense with material, will also not be considered for
remeshing.

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Advanced Topics

• Because AM octree adaptive meshing occurs during solution, the coarsened mesh is visible via
section plane only on results displays.

• The LPBF High Strain result is not available when using AM octree adaptive meshing.

6.4. Using Variable Layer Height

The variable layer height feature for additive manufacturing analyses allows you to vary the simulation's
layer height to build with smaller layers in areas of interest, and larger layers in other areas of the part.
You can capture fine details in a simulation without greatly increasing the overall simulation time by
reducing the number of super-layer load steps that need to be solved. (See Methodology and Abstrac-
tions (p. 7)). You control this by setting the layer size (AMBUILD,LAYERT) and number of simulation
layers to solve (AMSTEP,BUILD) iteratively until the part is complete.

Procedural Steps
This feature can be used by iteratively specifying the simulation layer size with the AMBUILD command,
and the number of layers to build with the AMSTEP command. In Mechanical, these commands can
be added to a Commands object under the analysis type. If variable layer height is used for a thermal-
structural analysis, both the thermal analysis and the structural analysis must have the same sequence
of layer sizes and layers built.

Create commands to use variable layer height:

1. Click the Static Structural object and select Commands from the context menu. Or, right-click
and select Insert > Commands. In the Commands window that is displayed, type something like
the following, modifying the specific numbers to fit your part:
! Build 10 layers at 1 mm
AMBUILD,LAYERT,0.05,1
AMSTEP,BUILD,,10

! Build 6 layers at 0.25 mm

AMBUILD,LAYERT,0.05,0.25
AMSTEP,BUILD,,6

! Build the remaining layers at 1mm

AMBUILD,LAYERT,0.05,1

Note:

By default, the Mechanical application will send the AMSTEP,BUILD command after
reading the Commands objects. If variable layer height is used in an independent script,
the AMSTEP,BUILD command will need to be added to the end of the example script
above.

2. Repeat the above step for the Transient Thermal system if you have a thermal-structural analysis.
(This step is not applicable for an AM simulation using Inherent Strain.)

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 Using Variable Layer Height

Example
Following is an example to illustrate the variable layer height feature. The simple part has three columns
that come together to form a beam at a height of 8 mm. We want to capture greater details at the
location where the columns join together because we suspect that is where the greatest distortion will
be.

Using a Commands object inserted under the static structural system, we set up simulation layers with
a height of 1 mm for the columns and a height of 0.25 mm after that for the beam. This simulation
uses Inherent Strain so there is no transient thermal system.

Our results show comparable distortion at the location of interest and the variable layer height feature
resulted in a 53.8% simulation time reduction for this model and variable layer height setup.

A. Full layer height B. Variable layer height

Mesh layer size = 0.25 mm Mesh layer size = 0.25 mm
Number of element layers = 40 Number of element layers = 40
Number of simulation layers = 40 Number of simulation layers = 15
Node count = 78,115 Node count = 78,115

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A. Full layer height B. Variable layer height

Element count = 52,376 Element count = 52,376
Solution time = 6 min 30 sec (10 cores) Solution time = 3 min 30 sec (10 cores)

Notes on Usage and Known Limitations

When using variable layer height:

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 Understanding Machine Learning Thermal Strain

• Using large layer thicknesses may lead to artificially high deformations. It’s always important to
carefully review your results.

• In some cases, it may be necessary to suppress an error check for elements spanning multiple layers.
Suppression for this check can be controlled in the AMBUILD,LAYERT command. A value of 1 can be
sent for the “Layer-checking suppression” field shown in the command input below. Be careful when
using this option as it may lead to improper boundary conditions. This is a beta option at this release.

AMBUILD,LAYERT,Deposition thickness,Super-layer thickness,Layer-checking

suppression

• The progress bar may not accurately track the progress of the simulation.

• At this release, the estimate of the real machine build time in the output file will probably be incorrect.

6.5. Understanding Machine Learning Thermal Strain

Thermal Strain simulations, specifically those run using Additive Print's Thermal Strain simulation type,
provide the highest level of fidelity at the cost of a much longer computational time. That is because
Thermal Strain simulations predict how thermal cycling affects strain accumulation at each location
within a part. The simulation follows the laser moving along each scan track on each deposit layer and
is based on the machine process parameters (power, scan speed, beam diameter, etc.). See Thermal
Strain - Anisotropic and Overview of the Thermal Solver in the Additive Print and Science User's Guide.

It can take millions of laser scan tracks to build a typical part with the laser powder bed fusion process,
and performing a thermal simulation that follows the laser along each scan track can easily incur a
computational cost that is prohibitive. Modern machine learning (ML) techniques provide a way to map
from the machine parameters and scan pattern directly to the final outcome, skipping the costly scan-
by-scan thermal simulation while providing a high-fidelity result that is computationally practical. Our
ML Thermal Strain model, based upon the Thermal Strain simulation type in Additive Print and imple-
mented in Workbench Additive, predicts the Thermal Strain result much faster than simulation. It can
be one to three orders of magnitude faster than Thermal Strain simulation in calculating the strain that
is passed to the structural solver. Speedup increases with part size, scan area, and melt pool size.

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The ML model is based on a deep convolutional neural network that has been trained on an extensive
database of Thermal Strain simulation results. No further data generation or training is required to use
ML Thermal Strain. The database used to pre-train the ML model consisted of nearly one million layers
from a variety of complex geometries. Machine parameters covered the entire range available when
defining build settings, and were restricted to combinations with predicted single bead melt pool di-
mensions that meet the following constraints:

• Single bead melt pool depth must be greater than or equal to deposition thickness

• Single bead melt pool width must be greater than or equal to hatch spacing

• Single bead melt pool width divided by single bead melt pool depth must be greater than or equal
to 1.25

When using ML Thermal Strain, violations of predicted single bead melt pool dimension constraints will
trigger messages that recommend how to adjust machine parameters to resolve the violations. Note
that the predicted single bead melt pool dimensions are an approximation and may not match results
from a Single Bead simulation in Additive Science.

Porosity is neglected. All locations within the part are assigned at least the base strain. For this reason,
and because the ML model is subject to error in approximating Thermal Strain results, ML Thermal
Strain results may not be an exact match with Thermal Strain results.

We recommend you perform a Strain Scaling Factor calibration specifically for ML Thermal Strain. Do
not use Strain Scaling Factor calibration that was completed for Thermal Strain.

Frequently Asked Questions

• How much of a speedup over Thermal Strain simulation can I expect when I choose ML Thermal Strain?

The following plot shows performance data for generating the thermal strain for one deposit layer in
a sample part run in various strain modes in the Additive application. For an average layer time of 1
second, it would take ~1000 seconds for a 1000-layer part to complete the thermal strain mapping
for the part. Overall, the speedup of strain generation with ML Thermal-Strain can be up to three
orders of magnitude faster than Thermal Strain simulation and is comparable in speed to the Scan
Pattern simulation type. Speedup increases with part size, scan area, and melt pool size. However, it
is important to remember that the speedup from ML Thermal Strain is applicable to the thermal
portion only of the overall simulation, and that the thermal strains are then passed to the structural
solver to determine stress and deformation. To determine the overall simulation time, you need to
add the time taken to solve the structural portion.

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 Understanding Machine Learning Thermal Strain

The following plot demonstrates that the speedup of ML Thermal Strain over Thermal Strain simulation
improves with increasing part size, scan area, and melt pool size. Melt pool width generally increases
as energy is input to the system, such as by increasing power and/or beam diameter, and/or decreasing
scan speed. As in the above plot, the data is from the generation of thermal strain for one deposit
layer, and this data is from two sample parts with two sets of process parameters run in the Additive
application. You can see a 20X to 4500X speedup in these scenarios.

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Advanced Topics

• Is the ML Thermal Strain capable of simulating my unique geometry without additional training?

Yes. Additional training is not needed. The ML model was trained with a collection of over 300 parts
representing a wide range of geometries including organic shapes, bulky and thin features, state
transitions, spiral and helical geometries, and many more.

• Is there a limited range of machine input parameters I should stay within?

Yes. The table below shows the required ranges and recommended ranges, if applicable, for the
machine parameters required for the ML model.

Parameter Required Range Recommended Range

Beam Power 50 to 700 Watts 50 to 500 Watts
Scan Speed 350 to 2500 mm/sec 500 to 2500 mm/sec
Beam Diameter 20 to 140 µm 80 to 120 µm
Deposition Thickness 10 to 100 µm
Hatch Spacing 60[a] to 1000 µm
Scan Stripe Width 1 to 100 mm
Start Layer Angle 0 to 180°
Layer Rotation Angle 0 to 180°

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 Performing a Directed Energy Deposition (DED) Process Simulation (Simplified Ap-
proach)

Parameter Required Range Recommended Range

Preheat Temperature 20 to 500 °C 20 to 200 °C
[a] Different than Thermal Strain in Ansys Additive

• What if I want to customize my material properties?

Since there are no material property inputs to the ML Model, we can only provide thermal strain
results based on the material properties used to train the models. These are the materials validated
for the Additive application. Choose the thermal Strain Material Model that most closely matches
your material and then be sure to perform a calibration for ML Thermal Strain.

• Why do I need to calibrate specifically for ML Thermal Strain? Are there any special considerations for ML
when performing a calibration?

Each simulation type represents a specific set of underlying assumptions. For example, an Inherent
Strain simulation with an Isotropic strain definition (referred to as the Assumed Strain simulation type
in Additive Print) is the most simplifying assumption about strain behavior within a part during a
build. More inputs are needed as the underlying assumptions become more complex for various
simulation types. A calibration process determines the factor(s) that work with any given set of as-
sumptions to get the best fit to your machine/material/part scenario. Therefore we recommend you
perform a calibration for each simulation type you will be performing. See Additive Calibration - Full
Procedure in the Additive Print and Science Calibration Guide. While the ML model was based on the
Thermal Strain simulation type in Additive Print, we do not guarantee that the ML model, as trained,
will always remain in sync with the Thermal Strain simulation type, as occasional tunings of the
Thermal Solver are performed.

There are no special considerations for ML when building a calibration part and taking measurements,
but be sure to choose ML Thermal Strain in Workbench Additive when running the simulation portion
of the calibration procedure.

Just as we state for all simulation types, it is not necessary to perform a calibration for ML Thermal
Strain if your goal is simply to examine trends, that is, the effects of variable changes on stress or
distortion relative to each other.

6.6. Performing a Directed Energy Deposition (DED) Process Simulation

(Simplified Approach)
Directed Energy Deposition (DED) is an additive manufacturing process where metal wire or powder is
combined with an energy source to deposit material onto a part directly. Rather than spreading a layer
of metal powder across a surface and scanning the part's profile with a laser to build up a part surrounded
by unmelted powder, only the desired part is built in a DED process, with no surrounding leftover
powder. The DED process is much less expensive than LPBF but less precise. It is widely used to repair,
or add extra material to, existing parts.

Important:

Ansys provides two methods of DED process simulation. The first is a simplified approach in
which super layers representing several actual welded layers are lumped together using the

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Advanced Topics

birth-and-death technique just as in an LPBF simulation. Most of the steps are the same, with
special considerations as described in this section.

The second approach is a more detailed and accurate representation in which the path of
each deposition weld track is "followed" using element clusters that are made alive using the
birth-and-death technique. This approach uses the DED Process Add-on. Refer to the dedicated
user's guide for details.

Simulation of a DED process using the simplified approach is almost the same as for an LPBF process,
except that the convection of heat from the part as it is being built must be accounted for differently.
Specifically, convection to the surrounding gas in the chamber is applied to all sides of the build as it
is building. (This differs from an LPBF simulation, in which the convection is applied only to the top of
a newly deposited layer.) A DED simulation uses only the gas convection properties of the build settings
and not the powder convection properties. All the required adjustments are handled automatically by
the program once you specify a DED simulation using the AMTYPE command.

At any point prior to solution, specify a DED simulation with a Commands object in both the transient
thermal and static structural analyses:

1. Click the Transient Thermal object and select Commands from the context menu. Or, right-
click and select Insert > Commands. In the Commands window that is displayed, copy and paste,
or type, the following:
AMTYPE,DED

2. Click the Static Structural object and select Commands from the context menu. Or, right-click
and select Insert > Commands. In the Commands window that is displayed, copy and paste, or
type, the following:
AMTYPE,DED

All other procedures for a DED simulation are the same as in an LPBF simulation.

6.7. Simulating Heat Treatment after the Build

After a part is built (3D printed), it is common to heat treat it to relieve residual stresses. Heat treating
is a process using the controlled application of heat to alter the physical and chemical properties of a
material. In an annealing process, metal is heated in a furnace to a particular high temperature, held
there for a long time (hours or days) and then allowed to cool slowly. This may be done either before
or after removing the part from the base plate. These scenarios can be simulated in Workbench Additive.

A separate, additional Transient Thermal analysis is required to model the heat treatment process. The
workflow is shown in the following figure. The systems in the workflow show how data flows from one
analysis type to another. For example, temperatures from the two (uncoupled) thermal analyses are
required as inputs for the structural analysis. It is within the AM Process Sequencer that the proper time
sequence—or when that data is used—is defined.

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 Simulating Heat Treatment after the Build

Overview

The modeling of heat treatment is included in the LPBF Setup Wizard. Below is an overview of the steps
required to simulate heat treatment after the build without using the wizard:

• Add a new Transient Thermal analysis system to the project schematic.

• Add a Heat Treatment Step in the AM Process Sequencer.

• Apply the convection loads to all bodies for the heat treatment step.

• Account for the stress relaxation mechanism in one of two ways:

– By specifying a Relaxation Temperature in the Static Structural analysis settings. This is a

simplified approach.

– By using a creep model in Engineering Data. This is a more stringent approach.

Add Transient Thermal System to Project

Assuming you have an AM Process Simulation already set up in Ansys Workbench:

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1. From the Analysis Systems folder, drag a new Transient Thermal system over the top of the existing
Transient Thermal system and release the mouse when the cursor is on the Model cell.

2. Link to the Static Structural system by dragging the Solution cell of the new Transient Thermal object
and release on the Setup cell of the Static Structural system.

3. Within the Mechanical application, click the new Transient Thermal object in the project tree and
in the Details view, under Additive Manufacturing, change the AM Process Simulation setting to No.
(By default, Mechanical assumes an AM Process Simulation should be performed for Transient Thermal
systems when there is an AM Process object in the project tree.)

Add Heat Treatment Step to the AM Process Sequencer

1. Select the AM Process object and then select the AM Process Sequence option on the context
toolbar.

2. Click Add Step on the Static Structural side of the Sequencer worksheet and select Heat Treatment
Step. Rearrange steps in the sequencer as needed.

3. Select the Static Structural object in the project tree and then select the Imported Load object
underneath it that belongs to the new heat treatment Transient Thermal system. In the Details view,
under Additive Manufacturing, change the Transfer Step option to your new Heat Treatment Step.

Apply Convection Loads

To apply convection to the surfaces of the part, supports, and base plate for the heat treatment step:

1. Right-click the new Transient Thermal object and then select Insert > Convection.

2. Select all the bodies including the base plate (geometry selection) and hit Apply in the Details view.

3. In Details under Definition, Film Coefficient, enter a value for the convection coefficient or select
Tabular Data.

4. Under Ambient Temperature, select Tabular Data.

5. In the Tabular Data area of the interface, specify the appropriate convection coefficient and tem-
perature at different time points.

6. In Analysis Settings, change the Step End Time to match the final time in the convection tabular
data. More details on how to control the time stepping settings are available here.

Identify Stress Relaxation Mechanism

To use a Relaxation Temperature as the mechanism for stress relief:

• Click Analysis Settings under the Static Structural object. In the Details view, under Additive Manu-
facturing Controls, change the Relaxation Temperature to User Specified and then change the
Value to your desired stress relaxation temperature for the material.

Alternatively, to use a creep model as the mechanism for stress relief:

1. From the Workbench Project page, double-click Engineering Data in the first Transient Thermal
analysis.

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 Simulating Heat Treatment after the Build

2. In the Toolbox window, expand the tab for Creep and drag your desired creep model to your ma-
terial. Enter information for all required fields before returning to the Project page.

3. Right-click the Model cell in the first Transient Thermal analysis and select Update before returning
to Mechanical.

Example Heat Treatment Project

The following heat treatment project was set up to show the effects that heat treatment can have on
stress and distortion in an additively manufactured part. Two cantilevers with supports are set up in
the same additive manufacturing simulation with cutoff from the supports occurring at different time
points for each cantilever. The first cantilever is removed from supports before heat treatment, and the
second cantilever is removed after heat treatment.

To model this, the AM Sequencer was set up as shown in the following figure.

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Advanced Topics

After simulating the additive manufacturing process and steps defined in the sequencer, the two canti-
levers are left with different distortion magnitudes. The heat treatment step relieved residual stresses
and led to decreased distortion in the second cantilever (on the left) after the cutoff step.

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 Capturing a Buckled Shape with Large Deflection

6.8. Capturing a Buckled Shape with Large Deflection

If your part has particularly thin walls and you are worried that it may deform significantly during the
additive printing process, you can set up a simulation to capture a buckled shape deformation. The
following two settings should be set to capture this phenomena in the AM simulation:

• Turn on Large Deflection: Under Static Structural, click Analysis Settings. In the Details view,
under Solver Controls, change Large Deflection to On. This setting is off by default for AM
simulations.

• Use Quadradic elements: Click Mesh, and in Details, under Defaults, change Element Order to
Quadradic. Higher-order elements may help convergence in the simulation.

The following figures show distortion results from an AM simulation of a model with a thin outer wall.
The full model is shown as well as a cross-section view. The upper portion shows significant distortion

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Advanced Topics

into a buckled shape. (Note: this model has a coarser mesh than recommended, it is for demonstration
purposes only.)

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 Modeling a Symmetrical Part

6.9. Modeling a Symmetrical Part

If your model has symmetrical geometry—specifically, if it is symmetric with respect to the part, supports,
and build plate, and it has symmetric loading and boundary conditions—you can simulate a sector of
a large model to achieve a faster simulation time with fewer resources. Both the base plate and the
build (part and supports) should be included in the symmetry sector.

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The procedure is the same as described in Defining Symmetry, with a few modifications for the AM
process simulation. Specifically, you will need to do the following:

A. Prepare your part, supports, and baseplate geometries to form a symmetric sector.

B. After meshing, create a SYMM_NODES named selection consisting of nodes along the symmetry
plane. This named selection is used internally and allows the program to handle the AM
boundary conditions properly.

C. As a structural boundary condition, apply a constraint at the symmetry plane of the build and
the base plate. Depending on the mesh type used, this is done in one of two ways:

• For a Cartesian mesh, where the mesh is associated back to the geometry entities, insert
a symmetry region on the geometry faces defining the symmetry planes.

• For a layered tetrahedral or voxel mesh, where the mesh is not associated back to the
geometry faces, define Mechanical APDL commands that constrain nodes from moving
normal to the symmetry planes.

D. Finally, if your simulation includes a thermal solution, input a Dwell Time Multiple in Build
Settings to account for the reduced simulation time that comes with a symmetry model.

For step A, prepare your model in a CAD package, as normal. Procedures for steps B through D are
described next.

Procedural Steps
B. Create a SYMM_NODES named selection consisting of nodes along the symmetry plane

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 Modeling a Symmetrical Part

Right-click Model in the project tree, and select Insert > Named Selection. Right-click the newly created
Selection object (under Named Selections) and Rename it to SYMM_NODES. In the Details view change
Scoping Method to Worksheet. In the Worksheet, set up filtering criteria to identify the nodes of interest.
In the half symmetry model below, we selected all the nodes along a plane of X = 0. Click Generate to
create the named selection of nodes.

C. Apply a constraint at the symmetry plane

• For a Cartesian mesh, insert a symmetry region on the faces defining the symmetry plane of the
build and the base plate. This will apply a frictionless support boundary condition on those faces.
With this boundary condition, no portion of the body can move, rotate, or deform normal to the
faces. (The use of a frictionless support is not unique to additive manufacturing simulations.)

Switch to face mode of selection and use Ctrl-left-click to select the multiple geometry faces
along the symmetry plane. Highlight Model, right-click and Insert > Symmetry. Right-click the
Symmetry object and select Insert > Symmetry Region. In the Details view, be sure that the
Symmetry Normal property is set to the axis of the Global Coordinate System that is normal to
the symmetry plane, in our example, the X-Axis.

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• For a layered tetrahedral or voxel mesh, since the mesh is not associated back to geometry faces,
planes of symmetry selected in the UI are not recognized. For these types of meshes, you must
define Mechanical APDL commands that constrain nodes in the symmetry planes. (Note that a
voxel mesh associates back to body entities only, not faces, edges, or vertexes.)

Right-click Static Structural and select Insert > Commands. On the Commands object that
appears in the tree, enter the appropriate commands that select the SYMM_NODES nodes, applies
a constraint (D command) to prevent motion normal to the symmetry plane, and selects all
nodes again. In our half symmetry example:
CMSEL,S,SYMM_NODES
D,ALL,UX,0
ALLSEL

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 Modeling a Symmetrical Part

D. For thermal simulations, input a Dwell Time Multiple equal to the number of symmetry sector
repeats

For analyses with thermal solutions, such as an AM LPBF Thermal-Structural simulation, this step is re-
quired to reconcile the reduced time to simulate the build. For example, the build time for a half sym-
metry model is ½ of the build time of the full model, so the Dwell Time Multiple should be 2. Similarly,
use a Dwell Time Multiple of 4 for a quarter symmetry model, and so on.

In the project tree, click AM Process > Build Settings and in the Details view under Machine Settings,
change Dwell Time Multiple to 2, or 4, or the appropriate number of repeats. In the half symmetry
model in our example, we changed Dwell Time Multiple to 2.

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Advanced Topics

The remaining steps are the same as usual for additive simulations.

6.10. Modeling Powder with Elements

During a laser powder bed fusion (LPBF) process, almost all the heat dissipation is through the part and
supports back to the build plate rather than out through the unmelted powder surrounding the part.
Many users ignore the small effect of heat loss through powder but you may choose to model it in one
of two ways:

• As equivalent heat convection

• By including powder elements as a named selection called POWDER_ELEMENTS. (For MAPDL

users, use an element component CM,POWDER_ELEMENTS,ELEM).

Modeling the powder as elements may be useful if you will be simulating multiple parts close together
on the build plate or if the part has features close together, where accounting for the heat transfer oc-
curring between the parts or features is important. The following is an overview of the procedure:

1. In your CAD program, create a separate body to represent the powder in-between the parts or fea-
tures. If you will be using a Cartesian mesh, share topology between the bodies. If you will be using
a layered Tetrahedrons mesh, do not share topology.

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 Modeling Powder with Elements

2. In the Mechanical application, identify the build and base bodies on the AM Process object as usual.
Do not select the powder body when identifying the build and base bodies.

3. Assign the same materiel property that you use for the build to the powder body.

4. Depending on your chosen mesh type, account for the connections between bodies and mesh the
model.

5. Create a named selection, called POWDER_ELEMENTS, of elements associated with the powder body.
This Ansys-defined named selection will use the knockdown factor, Powder Property Factor, identified
in the Build Conditions to estimate the powder properties.

6. Proceed with the rest of the simulation as normal.

In the following example, the powder was modeled between two cylindrical parts close together on
the build plate. Temperature contours are shown in the second figure. Notice the heat transfer in the
powder area between the parts.

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Advanced Topics

6.11. Modeling Clamps, Measuring Devices and Other "Non-Build" Com-

ponents
At times you may want to simulate geometry items that are present on the build plate but that are not
being 3D-printed. These items may include clamps, bolts, measuring devices, instrumentation, etc. They
may influence the heat dissipation and/or distortion of the part being built so they need to be included
in the simulation.

Use the Ansys-defined named selection NONBUILD_ELEMENTS to identify this geometry. (For MAPDL
users, use an element component CM,NONBUILD_ELEMENTS,ELEM). This Ansys-defined component name
signals to the application that those elements should not be part of the build process. That is, they will
be present the entire simulation and will not be "birthed" at melting temperature in a layer-by-layer
fashion.

6.12. Troubleshooting Convergence Issues

If you are experiencing convergence issues during an AM Process Simulation, try one or more of these
suggestions, as appropriate:

• If Large Deflection is on, turn it off, under Analysis Settings for the static structural analysis. Large
deflection is off by default for AM Process Simulations but it is useful in some cases and users often
turn it on.

– For thin-walled parts, the walls can tend to take on a buckled or dimpled shape as the build pro-
gresses. In these cases, large deflection is required and convergence difficulties may be seen. If
that is the case, you will need an adequate mesh to capture this deformation. Consider using a

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 Troubleshooting Convergence Issues

finer mesh or switch to a quadratic (midside-noded) element (Element Order in Mesh Details). See
Capturing a Buckled Shape with Large Deflection (p. 105) for details.

• Switch to the Direct Solver for Solver Type under Analysis Settings for the static structural analysis.

• If you are using customized materials, be sure you have defined a nominal strength at the melt
temperature, as a near zero modulus and/or yield strength could lead to convergence problems.
(Ansys predefined materials take care of this internally.)

• If using a Layered Tetrahedrons mesh with a geometry imported from an .stl file, be sure the faceted
geometry is cleaned up as much as possible. (See Cleanup of Facets (p. 13)). Depending on the
quality of the .stl file, you may see convergence issues because of poor tet elements created with
a "dirty" .stl file.

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Chapter 7: Performing a Calibration
Deformation values within additively manufactured parts vary across different machine and material
combinations in real-world fabrication scenarios, especially when considering the numerous laser powder
bed fusion (LPBF) machine manufacturers and powder material suppliers available. Before simulating
your production part, you should calibrate your simulation software to help reduce variability. Calibration
accounts for the difference between measured and simulated deformation.

The overall calibration process for Workbench Additive consists of obtaining measured distortion values
from physical experiments and then performing a calibration simulation. The first part of the process,
obtaining measured distortion from a calibration build, is exactly the same process as described in the
Additive Print and Science Calibration Guide. Refer to the following topics from that document for details:

• Determine Your Calibration Part

• Appendix B: Download Calibration Files Here

• Build the Calibration Parts

• Take Distortion Measurements

The objective of this calibration procedure is to determine a set of calibration coefficients to use when
performing simulations in Ansys Workbench Additive. The coefficients to be determined depend on
the simulation type and strain definition selected. This is summarized in the following table. SSF is Strain
Scaling Factor and ASC is Anisotropic Scaling Coefficient. Throughout this document, we will distinguish
between an SSF/TSSF-only calibration and an SSF combined with ASCs (or SSF + ASCs) calibration.

Calibration Simulation type / Strain

Calibration Coefficients
Type definition
AM LPBF Inherent Strain / SSF
- - -
Isotropic
SSF only
AM LPBF Thermal-Structural Thermal SSF
- - -
(TSSF)
AM LPBF Inherent Strain / SSF Parallel Perpendicular Vertical ASC
SSF + Scan Pattern ASC ASC =1
ASCs AM LPBF Inherent Strain / SSF Parallel Perpendicular Vertical ASC
Thermal Strain ASC ASC =1

The values of the calibration coefficient(s) compensate for the difference between an experimentally
measured target deformation and a simulated deformation value obtained at the same location on a
chosen calibration geometry. Using the calibrated coefficient(s) will greatly improve the simulation
prediction accuracy of your production part when using the same simulation setting combinations,
therefore increasing the chance of successful builds as well as reducing the cost of trial-and-error exper-
iments.

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Performing a Calibration

See the beginning of this section (p. 86) for more information about calibration coefficients.

7.1. When to Calibrate

The values for calibration coefficients depend upon many variables from both fabrication and simulation
setup:

• Material

• LPBF machine

• Process parameters (laser power, scan speed, deposition thickness, base plate preheat temperature,
hatch spacing, etc.)

• Simulation type and strain definition

• Material properties (linear or nonlinear)

• Mesh type (Cartesian, layered tetrahedrons, or voxel)

• Other simulation specific configurations

Calibrate only for the type of simulation you will be performing on your production part. For example,
if you care about the as-built distortion of a part for a given material, machine, and process parameter
combination using an Inherent Strain isotropic simulation, run the calibration just for that combination
of variables. When the combination changes, re-calibrate the calibration coefficients. Even changing
the material supplier for a material you have already calibrated for may require a new calibration.

It is important to note that you can expect different calibration coefficient values from different simulation
types, material properties, and/or mesh types even when using the same experimental distortion
measurement value(s).

7.2. Calibration Simulation Workflow

The steps in a calibration simulation are summarized here and described in more detail following the
table.

Calibration Simulation Workflow at a Glance

Simulation Step Considerations for Calibration
1. Set up AM simulation Set up either an LPBF Thermal-Structural or LPBF Inherent Strain
simulation. Import your chosen calibration geometry. Use the LPBF
Setup Wizard (p. 17) to set up your simulation the same as you
would to simulate your production part.

For the meshing step, use a 0.5 mm voxel mesh size if you are
using either the Cantilever or Double arches calibration
geometry from Ansys.

Use defaults for all calibration values.

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 Calibration Simulation Workflow

Calibration Simulation Workflow at a Glance

Simulation Step Considerations for Calibration
Perform the steps in the wizard until you reach the last step,
Set Up Calibration.
2. Set up calibration Set Set up Calibration to Yes.

The last step of the LPBF Setup Identify Node Measurement Location, such as a line of nodes
Wizard is the same as the along a surface, corresponding to the experimental
single-step LPBF Calibration measurement location.
Wizard.
Choose Deformation Direction, either X, Y, or Z in which
deformation is measured. Usually this is normal to the surface
of the measurement location.

Set Calibration Deformation Results, either Max, Min, or Avg

Calibration Type (either SSF or SSF + ASCs) is set automatically

based on your settings of simulation type and Strain Definition.

Set up Start Layer Angle and Layer Rotate Angle if SSF +

ASC mode is chosen.

Set Target EXP Deformation, the target deformation value.

Set Calibration Tolerance, an acceptable level of difference

between experimental and simulated deformation.
3. Solve the calibration simulation In Workbench, right-click Optimization > Update in the Direct
Optimization system to initiate the calibration. Calibration iterations
are fully automatic.

Requires an Additive Suite license

4. View and save optimized Record the last set of parameters and then Save Build Settings.
calibration coefficients

Details of Workflow
Let's look at the workflow to run a calibration simulation in Workbench Additive in a little more detail.

1. Set up either an LPBF Thermal-Structural or LPBF Inherent Strain simulation. See Create the
Analysis System (p. 21).

2. Import your chosen calibration geometry.

3. Use the LPBF Setup Wizard (p. 17) to set up your simulation the same as you would to simulate
your production part. Refer to the Help information at the bottom of each wizard page for details.

4. There are a few preferred mesh types for LPBF simulations. See Apply Mesh Controls and Gen-
erate Mesh (p. 30). Mesh type and size affect results convergence. For best results, we recom-
mend you use the same mesh type for the calibration simulation that you will use for the sim-
ulation of your production part.

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Performing a Calibration

These are our mesh size recommendations for the Ansys-supplied Cantilever and Double arches
calibration geometries:

Geometry Mesh type Mesh size Layer height Projection

(mm) (mm) Factor
Voxel 0.5 - -
Double Layered 0.5 0.5 -
arches tetrahedrons
Cartesian 0.5 - 0
Voxel 0.5 - -
Layered 0.75 0.75 -
Cantilever
tetrahedrons
Cartesian 0.5 0

5. The selections you make in the Build Settings step determine whether you will need a SSF/TSSF-
only calibration or an SSF + ASCs calibration.

Note that the Inherent Strain Definition of Anisotropic is not available/supported for automatic
calibration.

6. Use default values for calibration coefficients.

7. The last step of the LPBF Setup Wizard is the calibration set-up. Follow the instructions in the
Help section to complete the settings.

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 Calibration Simulation Workflow

Set up Calibration = Yes

Node Measurement Location: Use geometry selection or named selection to identify the nodes
corresponding to the measurement location. Directional deformation data will be extracted

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Performing a Calibration

here for comparison to the target EXP deformation values. It may be easiest to define a named
selection based on geometric location such as a line of nodes along an edge located at X=0
and Y=5 mm, for example. Refer to the tutorial for an example.

Deformation Direction: The direction, either X, Y, or Z, in which deformation is measured.

Usually this is normal to the surface of the measurement location.

Calibration Tolerance: An acceptable level of difference between experimental and simulated

deformation. Defaults to 1%.

Calibration Deformation Results: Either Max, Min, or Avg. Choose this input to match the data
you measured.

Calibration Type: Either SSF or SSF + ASCs. This is set automatically based on your settings of
simulation type and Strain Definition.

Target EXP Deformation: The target deformation value.

8. Once all the required settings are configured, click Finish and close the wizard. Proceed back
to Workbench UI. For the calibration iterations, a pre-configured Direct Optimization system is
added to the project and linked to the AM simulation system.

In Workbench, right-click Optimization > Update in the Direct Optimization system. The op-
timization will start to run calibration iterations automatically. Depending on the calibration
mode you are using, either a one step SSF/TSSF-only calibration or a two-step SSF + ASCs cal-
ibration is performed.

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 Calibration Simulation Workflow

9. To check the progress during calibration iterations, double-click Optimization (in the Direct
Optimization system) and click Raw Optimization Data.

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Performing a Calibration

10. Once the optimization is completed, you will see the yellow lightening bolt become a green
check mark in the Direct Optimization system. In the Optimization tab, click Candidate Points.
The optimized values for calibration coefficients with their corresponding simulation deformation
values will be shown on the right.

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 Known Limitations

11. We recommend that you save the optimized SSF and ASC values for use in future simulations
of production parts. Use them whenever you simulate with the same set of variables for which
you calibrated. See When to Calibrate (p. 118).

In Workbench, double-click Parameter Set. Click inside the last row, then right-click and choose
Set Update Order by Row. Set to Current. Back in the Mechanical application, right-click Build
Settings in the project tree and select Save Build Settings. This will save the entire set of build
parameters including the optimized calibration coefficients.

7.3. Known Limitations

• The Inherent Strain Definition of Anisotropic is not available/supported in the LPBF Calibration Wizard.

• For calibrations that use cutoff results as target deformation values, turning on large deflection
(Static Structural > Analysis Settings under Solver Controls) is a reasonable option to consider. However,
convergence issues may arise from time to time during the calibration process.

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 Release 2023 R1 - © ANSYS, Inc. All rights reserved. - Contains proprietary and confidential information
126 of ANSYS, Inc. and its subsidiaries and affiliates.