Additive Prep User's Guide

ANSYS, Inc. Release 2023 R1

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Table of Contents
1. Introduction ............................................................................................................................................ 1
1.1. Licensing Notes ................................................................................................................................ 1
1.2. Assumptions and Restrictions ........................................................................................................... 2
1.3. Steps in the Additive Prep Process ..................................................................................................... 3
2. Create Build Volume ................................................................................................................................ 5
2.1. Checking for Problems with Faceted Bodies ...................................................................................... 7
2.2. Moving a Part into Position on the Baseplate ..................................................................................... 8
2.3. Working with Multiple Parts ............................................................................................................ 10
2.4. Build Volume Settings ..................................................................................................................... 13
3. Orient Part ............................................................................................................................................. 17
3.1. Orientation Maps ............................................................................................................................ 17
3.2. Orienting a Part .............................................................................................................................. 20
4. Create Support Regions ........................................................................................................................ 25
4.1. Creating Support Regions ............................................................................................................... 27
4.2. Editing Support Regions ................................................................................................................. 28
4.3. Deleting Support Regions ............................................................................................................... 29
5. Generate Supports ................................................................................................................................ 31
5.1. Support Types ................................................................................................................................ 31
5.2. Generating Supports ...................................................................................................................... 37
5.3. Generating Supports — Guidelines and Troubleshooting ................................................................ 39
5.4. Changing Support Parameters ........................................................................................................ 41
5.4.1. General Parameters ................................................................................................................ 42
5.4.2. Parameters for Block Supports ................................................................................................ 49
5.4.2.1. Parameters for Block Supports (Contour) ........................................................................ 55
5.4.3. Parameters for Adaptive Cell Supports .................................................................................... 59
5.4.4. Parameters for Line Supports .................................................................................................. 67
5.4.5. Parameters for Rod Supports .................................................................................................. 72
5.4.5.1. Parameters for Rod Supports (Contour) .......................................................................... 79
5.4.6. Parameters for Tree Supports .................................................................................................. 83
5.4.7. Parameters for Contour-only Supports .................................................................................... 93
5.5. Deleting Supports .......................................................................................................................... 98
6. Generate a Build File ............................................................................................................................. 99
6.1. Generating a Build File for SLM Machines ........................................................................................ 99
6.1.1. Defining a Build Strategy ...................................................................................................... 100
6.1.2. Changing Build Process Parameters ...................................................................................... 101
6.1.2.1. Scaling Parameters ...................................................................................................... 101
6.1.2.2. Slicing Parameters ....................................................................................................... 102
6.1.2.2.1. General ............................................................................................................... 102
6.1.2.2.2. Contour Filter ...................................................................................................... 103
6.1.2.2.3. Offset ................................................................................................................. 104
6.1.2.3. Volume Parameters ...................................................................................................... 105
6.1.2.3.1. General ............................................................................................................... 106
6.1.2.3.2. Stripes ................................................................................................................ 106
6.1.2.3.3. Chess .................................................................................................................. 109
6.1.2.3.4. Parallel ................................................................................................................ 112
6.1.2.3.5. Rotation .............................................................................................................. 114
6.1.2.3.6. Border ................................................................................................................ 116
6.1.2.3.7. Blocked Paths ..................................................................................................... 117
6.1.2.4. Up-skin Remelting Parameters ..................................................................................... 118

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Additive Prep

6.1.2.4.1. General ............................................................................................................... 119

6.1.2.4.2. Stripes ................................................................................................................ 120
6.1.2.4.3. Chess .................................................................................................................. 123
6.1.2.4.4. Parallel ................................................................................................................ 127
6.1.2.4.5. Rotation .............................................................................................................. 129
6.1.2.4.6. Border ................................................................................................................ 131
6.1.2.5. Up-skin Recoating Parameters ..................................................................................... 131
6.1.2.5.1. General ............................................................................................................... 132
6.1.2.5.2. Stripes ................................................................................................................ 133
6.1.2.5.3. Chess .................................................................................................................. 135
6.1.2.5.4. Parallel ................................................................................................................ 138
6.1.2.5.5. Rotation .............................................................................................................. 140
6.1.2.5.6. Border ................................................................................................................ 142
6.1.2.6. Down-skin Parameters ................................................................................................. 142
6.1.2.6.1. General ............................................................................................................... 143
6.1.2.6.2. Stripes ................................................................................................................ 144
6.1.2.6.3. Chess .................................................................................................................. 147
6.1.2.6.4. Parallel ................................................................................................................ 150
6.1.2.6.5. Rotation .............................................................................................................. 151
6.1.2.7. Support Parameters ..................................................................................................... 153
6.1.2.7.1. Support .............................................................................................................. 153
6.1.2.7.2. Filter ................................................................................................................... 154
6.1.2.8. Scanning Parameters ................................................................................................... 155
6.2. Generating a Build File for EOS Machines ....................................................................................... 158
6.3. Generating a Build File for Renishaw Machines .............................................................................. 160
7. View the Build File with the Slice Viewer ............................................................................................. 163
8. Estimate Costs of the Build Job ........................................................................................................... 167
9. Export for Simulation or Print ............................................................................................................. 171
9.1. Export the Full Set of Files ............................................................................................................. 171
9.1.1. Recommended Workflow with Additive Print ........................................................................ 172
9.1.2. Recommended Workflow with Workbench Additive .............................................................. 173
9.2. Export CLI Files ............................................................................................................................. 177
10. Customize Additive Prep Startup Options ........................................................................................ 179
10.1. General Options .......................................................................................................................... 180
10.2. Machine Options ......................................................................................................................... 183
10.3. Material Options ......................................................................................................................... 189

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Chapter 1: Introduction
Ansys Additive Prep is a tool that allows you to prepare parts that will be additively manufactured.
Additive Prep is built into Ansys SpaceClaim and tightly integrated into the additive workflow, whether
you will be continuing your workflow by simulating the AM process or sending your part(s) directly to
the build chamber. Orient your part(s) based on your priorities of build time, volume of supports, and
distortion tendency, and then automatically generate supports for them. Adjust your build strategy and
parameters, generate a build file and then view and animate the scan vectors within a slice or the slices
within a build in the Slice Viewer. The resulting optimally oriented parts and supports with associated
scan pattern are ready for print or for simulation using Additive Print or Workbench Additive.

1.1. Licensing Notes

The Additive Prep application is implemented as a tab in SpaceClaim. You need to have an appropriate
license for the Additive tab to appear. Additive Prep is included with Additive Suite and Additive Print
licenses. It is also available separately as an add-on to SpaceClaim. See your Ansys Channel Partner to
find out about your licensing options.

Even if you have a proper license, the Additive Prep application is not enabled by default. To enable
the application, in SpaceClaim, click File > SpaceClaim Options > License and then check Additive
Prep. Click OK. (If the Additive Prep option appears grayed out, it means you do not have a proper li-
cense.) The option is "sticky" in that once you have checked the box, it will remain checked each time
you open SpaceClaim, until you clear the box.

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Introduction

1.2. Assumptions and Restrictions

Assumptions:

• You do not need to be familiar with using SpaceClaim to use Additive Prep. The application is
mostly self-contained within one tab in the SpaceClaim interface. However, for reference, refer
to the SpaceClaim documentation.

• The units system assumed in the Additive Prep application is the Metric system using millimeters.

Regardless of whether your part is a design body (.scdoc) or a faceted body (.stl), dimensions of
the part must be in units of millimeters (mm) for Additive Prep’s internal calculations. While .stl
files are unitless, the SpaceClaim application has to assign a unit system to .stl files for certain
functionality to work. If you are creating new geometry in SpaceClaim it will use the units that
are set under SpaceClaim Options > Units. This should be set to millimeters if you will be
working in Additive Prep. However, there is also an option to override units when saving an .stl
file from SpaceClaim. So if you are starting with an existing .stl file, it is possible it may have been
saved from SpaceClaim in units other than millimeters. If this is the case, you will need to re-save
the .stl file from SpaceClaim in millimeters before bringing it into Additive Prep.

General Restrictions/Limitations:

• Occasionally there may be known limitations associated with a particular feature in Additive
Prep. Those will be noted in this guide where applicable.

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 Steps in the Additive Prep Process

1.3. Steps in the Additive Prep Process

The functions in the Additive Prep user interface follow a typical workflow. You generally work through
the necessary steps for 3D print preparation from left to right and the steps build on each other. You
are free to skip certain steps if they are not needed. Similarly, you may revisit previous steps as required.

Preparing your build can be done in these steps.

1. Create Build Volume:

• Set up a Build Volume in the Structure tree representing the build chamber that will eventually
include a baseplate, your part, and any generated supports.

• Add additional parts into the Build Volume, as desired.

• Select your machine and material.

2. Orient Part: Optimally orient your part in the Build Volume using orientation maps that factor in
your priorities of build time, volume of supports, and distortion tendency.

3. Generate Supports:

• Once you have oriented your part, create regions that require supports based on overhang angle
and region size criteria. Or manually draw your own support regions for more precise control.
Support regions are the means by which supports are generated.

• Generate supports automatically from the support regions using a combination of several support
types with associated parameters.

4. Generate a Build File:

• Use the Build Processor to specify various build process parameters and generate a build file.

• Use the Slice Viewer to view and/or animate the progression of laser scan vectors across any slice
within the part, or the sequential build of all the 2D slices in the Build Volume.

• Run the Cost Estimator to calculate the costs for the build job based on the build file, your mater-
ial, a profit allowance, and machine-specific costs. The Cost Estimator is limited to only SLM ma-
chines at this release.

5. Export for Simulation or Print: Export the project files for simulation in Additive Print or Workbench
Additive, or for printing directly to a machine.

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Chapter 2: Create Build Volume

You can create or import a part in SpaceClaim before you begin using Additive Prep, or after, depending
on your preferences.

1. Click the Additive tab to begin using Additive Prep.

• If you do not see the Additive tab, check to be sure you have the correct license (p. 1).

• Only one body can be included when you create the Build Volume. If multiple bodies are detected
you will see an error message saying "Could not properly import..." Use the Add Part button once
the Build Volume is created to add additional parts. See Working with Multiple Parts (p. 10).

• You will need to unlock the part object if it is locked. Locked objects display a tiny lock icon in
the Structure tree. Right-click the solid in the Structure tree and select Unlock.

2. Click Create to establish the Build Volume. Doing so creates new components in the Structure tree.
The Build Volume will be empty or will contain your part, depending on whether or not you had a
part before you clicked Create.

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Create Build Volume

Note:

Throughout your use of Additive Prep, as new objects are added to the Structure tree
you will need to expand their parent object to see them. This is different behavior than
what you might be used to in SpaceClaim.

Build Volume: The overall project assembly including everything listed below:

• Baseplate: This is the plate, or build platform, at the bottom of the build chamber. You can
adjust the size of the baseplate under Settings > Manage Machines.

• Machine: An assembly that holds the machine information.

– Recoater Symbol: Shows the direction the recoater travels. This is a fixed symbol only,
shown for your reference. You cannot change the recoater direction here. The recoater
direction is inherent within the machine you select.

– Gasflow Symbol: Shows the direction the gas flows. Gas flow is essential to removing
soot from the build chamber. This is a fixed symbol only, shown for your reference.

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 Checking for Problems with Faceted Bodies

You cannot change the gas flow direction here. The gas flow direction is inherent
within the machine you select.

– Default (machine name): An object representing your machine configuration. If you

already defined a default machine in the SpaceClaim startup options (under Additive
Prep Machines), then that machine name is shown here. Click Settings to select a
machine other than the default.

• Workspace: The assembly consisting of your part, the Support Regions component, and the
Supports component for that part:

– Part: Your part geometry, which is usually either a faceted part (.stl file) or a SpaceClaim
NURBS-based geometry (.scdoc file), sometimes called a design body.

– Support Regions component: A component that will hold Support Region objects.
Support regions are created using the Create Regions (p. 25) tool under Support
Generation in the UI ribbon.

– Supports component: A component that will hold Support objects. Supports are
created using the Create Support (p. 31) tool under Support Generation in the UI
ribbon.

As you add additional parts to the Build Volume, new workspace assemblies will be added.

3. Click Add Part if you want to add another part to the Build Volume. See Working with Multiple
Parts (p. 10) for details.

4. Click Settings to bring up the Settings panel where you select your machine. See Build Volume
Settings (p. 13) for details.

Note:

Use the Preserve Original Model Document On Create (p. 181) option to open a new document
(a tab at the bottom of the user interface) when you click Create to create the Build Volume.
This is a good option when you want to preserve the original part because the design has
been approved or certified, for example.

Note:

We recommend using a separate session of SpaceClaim for each instance of an Additive Prep
Build Volume.

2.1. Checking for Problems with Faceted Bodies

If you have a faceted body (such as from an .stl file), we highly recommend you check the part for
problems before using Additive Prep. A little yellow triangle icon next to the Facets object indicates there
is a problem with your faceted part. Problems detected include:

• Multiple pieces (facet regions or shells)

• Non-watertight facets

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Create Build Volume

• Self intersections

• Over-connected (non-manifold) edges

Use the tools under the SpaceClaim Facets tab, Cleanup group to fix this.

2.2. Moving a Part into Position on the Baseplate

Part orientation and location on the baseplate are very important considerations in additive printing.

• To locate the part in X-Y plane on the baseplate — Use the standard SpaceClaim Move tool.
Select the workspace assembly you'd like to move, then click the Design tab (one of the
SpaceClaim tabs) and in the Edit group, click Move to use the Move tool. Select an X or Y
translational axis on the Move handle and drag the part to the appropriate location. Repeat as
needed.

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 Moving a Part into Position on the Baseplate

If the part already has supports, the supports are moved with the part, provided the workspace
is selected in the Structure tree. If only the part is selected, and not the entire workspace, the
supports are removed when you move the part and you will need to regenerate the supports
after moving the part.

• To locate the part up and down in the Z direction on the baseplate — Use the Z-Offset slider in
the Current Settings Orientation Map. See Orienting a Part (p. 20). Do not use the Move tool as
this will invalidate Additive Prep's orientation and support generation tools.

• To rotate the part on an axis — Use the positioning slider in the Current Settings Orientation
Map. See Orienting a Part (p. 20). Do not use the Move tool as this will invalidate Additive Prep's
orientation and support generation tools.

Automatic Out-of-bounds and Collision Detection

For design bodies, Additive Prep automatically checks the position of your part and highlights the part
in red in the following cases:

• When the part is outside the boundaries of the Build Volume (length, width, or height)

• For multiple parts (p. 10), when they are moved within the Build Volume such that they collide
with each other

• When a collision occurs between the part and the part-free areas (p. 186)

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Create Build Volume

A warning message describing the auto-detection is also provided in the blue status bar at the bottom
of the screen.

Important:

These automatic detections are calculated for design bodies only (.scdoc) and do not occur
for faceted bodies (.stl), which includes supports.

2.3. Working with Multiple Parts

With Additive Prep, it's easy to nest multiple parts within the Build Volume so that you can consider
the positioning of the parts when deciding how best to generate supports. You may add a new part
(to the part already in the Build Volume) or copy a part but there is an important distinction between
the two operations. Adding a part allows individual adjustments to the orientations and supports.
Copying a part maintains identical settings for orientation and supports of the original and the copied
parts. Regardless of which method you choose, be sure it is the entire workspace you are operating on
rather than the part only.

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 Working with Multiple Parts

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Create Build Volume

Adding an Additional Part (Workspace)

1. Click Add Part to add another part into the Build Volume. This will create a second workspace as-
sembly in the Structure tree within the Build Volume. (Adding a part with the same name as an ex-
isting part places a (1) after the new object name in the tree, or a (2) if it is the third copy, and so
on.)

Each new workspace is placed at the Zero Point (p. 185), either at the center of the baseplate or at
the corner, depending on what is selected in Settings under Zero Point. Most likely, the new part
will be placed directly on top of the first so you will need to move the workspaces around a bit.

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 Build Volume Settings

2. Select the workspace assembly you'd like to move, then click the Design tab (one of the SpaceClaim
tabs) and in the Edit group, click Move to use the Move tool. Select an X or Y translational axis on
the Move handle and drag the part to the appropriate location. Repeat as needed. To move the
part up or down in the Z direction, or to rotate parts, use the orientation map (p. 20), do not use
the Move tool as this will invalidate Additive Prep's orientation and support generation tools.

3. Once the workspaces have been moved into position, proceed to orient the individual parts, create
support regions, and generate supports as usual.

Copying a Part (Workspace)

1. Select the workspace assembly you'd like to copy, click Ctrl C, select the Build Volume assembly and
click Ctrl V. This will create a copy of the workspace assembly in the Structure tree within the Build
Volume. The copied workspace is placed directly on top of the first one so you will need to move
the workspaces around a bit.

2. Select the workspace assembly you'd like to move, then click the Design tab (one of the SpaceClaim
tabs) and in the Edit group, click Move to use the Move tool. Select an X or Y translational axis on
the Move handle and drag the part to the appropriate location. Repeat as needed. To move the
part up or down in the Z direction, or to rotate parts, use the orientation map (p. 20), do not use
the Move tool as this will invalidate Additive Prep's orientation and support generation tools.

3. Once the workspaces have been moved into position, proceed to orient the original part, create
support regions, and generate supports as usual but know that any adjustments you make to the
original part will automatically be made to the copied parts.

2.4. Build Volume Settings

Click Settings in the ribbon to bring up the Settings panel where you can select your machine for this
Build Volume and edit common machine settings.

Under Select Machine, select one of the machines from the drop-down menu. Options include the
default machine and your custom machines. Whether you have only one additive manufacturing machine,
or many, the number of variables and settings associated with the additive process can be overwhelming.
The Additive Prep application includes templates for various machines from which to choose. Our re-
commendation is to immediately narrow your options to just those machines that you have at your
facility to populate your custom machine user profile. Additionally, set one preferred machine as the
default in the startup options (p. 179) so that each time you begin a new Additive Prep session, your
preferred machine will be the default.

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Create Build Volume

If you want to edit some common machine settings of the currently selected machine from here, click
Edit Machine. Change settings as needed and then click Save Changes.

Click Manage Machines to access the machine form if you want to make changes to more advanced
options for your custom machines. This is the same form that you will find under File > SpaceClaim
Options > Additive Prep Machines (p. 183).

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 Build Volume Settings

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Chapter 3: Orient Part

One of the most challenging tasks of additively manufacturing an expensive metal part is knowing how
to orient it on the baseplate. You will want to maximize efficiency by orienting your part to:

• Reduce time to build

• Reduce material use and time needed to remove supports

• Reduce the distortion caused by residual stresses inherent in the process

• Reduce shadow area to enable more parts to occupy the build chamber

• Improve build precision by decreasing stair-step error

All while avoiding failures.

In Additive Prep, orientation maps help you to determine the best orientation for your part. Choose
the three factors that are most relevant to you from five possible factors: build time, volume of supports,
distortion tendency, stair-step error, and shadow area. Since the factors are competing, set your priorities
using the weighting triangle.

3.1. Orientation Maps

Orient parts in the build chamber using orientation maps. Choose the three priorities that are most
relevant to you, weight those three priorities to produce a composite map from your settings, then
orient the part according to the combined settings.

Five orientation maps are available:

• Build Time

• Support Volume

• Distortion Tendency

• Shadow Area

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Orient Part

• Stair-step Error

Several heat maps are shown in the orientation map panel. The maps use different colors to display
the effect of different orientation options. The colors indicate whether the orientation of the part is
good or in need of optimization. Green indicates optimum orientation. Red indicates an orientation
that is not recommended. The larger orientation map at the top of the panel (Combined Current Settings)
shows the values of the three options you have chosen, combined according to the prioritization
weightings you choose.

The horizontal axis of any orientation map shows the rotation of the part around the X-axis from 0° to
180°. The vertical axis shows rotation of the part around the Z-axis from 0° to 360°. All possible orient-
ations of the part are possible using these two axes of rotation together.

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 Orientation Maps

Combined Current Settings Orientation Map

An overall orientation map reflecting the combined current prioritization weightings you establish in the
weighting triangle for the three orientation options you select. If, for example, the weighting is completely
based on build time, the Combined Current Settings and Build Time orientation maps match. By default,
the Combined Current Settings orientation map is set to reflect relatively even weighting from all three
selected priorities, that is, 33% priority for the first option, 34% for the second option, and 33% for the
third option.

The current orientation of the part is marked by the crosshairs on this orientation map. To change the
orientation of the part, click in the map, drag the crosshairs to a new location on the map, or change
the numerical Rotation settings below the map.

Z-Offset
Z-Offset is the distance (in millimeters) from the current lowest point of the part to the baseplate. The
default Z-Offset is set to 5 mm. If you modify the rotation settings of the part so that the distance
between the baseplate and the part changes, the location of the part is moved to maintain this offset.

Prioritization Triangle
Use the triangular weighting tool used to assign priorities to the three options you select. This tool
adjusts the overall Combined Current Settings orientation map. Weights are distributed depending on
the position of the crosshairs in the triangle. You can drag the crosshairs or change the numerical settings
to modify the weighting. By default, the triangle is balanced to reflect even weighting for all three pri-
orities, that is, roughly one third (32% to 34%) for each.

Orientation Map Options

Five orientation maps are available, but only three may be selected. Choose an option from the drop-
down menu for each orientation map. Each option has a unique icon that represents that option on
the prioritization triangle. You cannot choose the same option for more than one orientation map. If
you are only concerned with one or two options, modify the prioritization triangle to de-emphasize the
orientation map or maps that are of less concern to you.

Build Time

A color-coded map of part orientation around the X and Z-axes based on the relative amount of
time it will take to build the part in that orientation. Green areas on the map indicate orientations
that will build faster. Red areas denote orientations that will take more time to build..

Supports

A color-coded map of part orientation around the X and Z-axes based on the relative amount of
supports (p. 31) needed to build the part in that orientation. Green areas on the map denote ori-
entations that require fewer supports. Red areas denote orientations that require a greater volume
of supports.

The calculation is based on the total volume to be supported. The Overhang Angle (p. 25) is used
to determine the surfaces to be supported and then supports are projected to the baseplate creating

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Orient Part

a total support volume. The Overhang Angle is set in the Settings option under Build Volume (p. 5)
in the UI ribbon. By default, Overhang Angle is 40°.

Distortion Tendency

A color-coded map of part orientation around the X and Z-axes based on potential distortion of
the part if built in that orientation. Distortion tendency is not calculated based on a simulation but
on a simplified, proprietary calculation that approximates potential for distortion. Green areas on
the map denote orientations that will have less distortion tendency. Red areas denote orientations
that will have a greater tendency for distortion.

Stair-step Error

A color-coded map of part orientation around the X and Z-axes based on the relative overall amount
of stair-step error in the part if built in that orientation. Additive manufacturing introduces stair-
step error caused by the slicing of the component into layers, as indicated in the following figure.
The error is 0 for surfaces with 0° and 90° to the build direction. The error is highest for surfaces at
an angle of 45°.

Green areas on the orientation map indicate orientations that will result in less overall stair-step
error. Red areas on the orientation map indicate orientations that will result in more overall stair-
step error.

Shadow area

A color-coded map of part orientation around the X and Z-axes based on the relative overall build
plate area that will be occupied by the part if built in that orientation. When trying to fill a platform
with a maximum number of individual parts, you may wish to orient each part so that it blocks a
minimal area on the build plate. Green areas on the map denote orientations that require less build
plate area. Red areas on the map denote orientations that require more area on the build plate.

3.2. Orienting a Part

Before you can orient the part, you must select the Workspace (or any of the components in the
workspace assembly) to use the orientation maps. Click Orientation Map to bring up the orientation
map panel. The calculations begin immediately. It may take several minutes for the orientation maps
to populate initially, depending on the complexity of your part. If your part is in .stl format already, the
Additive Prep application will use those facets to perform its operations. If your part is in SpaceClaim's
.scdoc format, or any non-faceted format, the application will first convert it to facets. You may see a
status window showing the progress of the faceting operation as shown here.

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 Orienting a Part

The following steps reflect the typical sequence for orienting a part but you may perform them in any
order.

1. Drag the slider, or use the numeric input field, to set the Z-Offset (the distance between the lowest
point of the part and the baseplate). When you rotate your part in the Combined Current Settings
orientation map, the position of the part will automatically be adjusted to maintain the Z-Offset
value.

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Orient Part

2. If the three orientation maps shown do not reflect your priorities, select other orientation map options
from the drop-down menus. See the section "Orientation Map Options (p. 19)" for more information
on available options.

3. Drag the crosshairs in the prioritization triangle, or use the numeric input fields, to adjust the
weighting of priority among the three orientation maps. The higher the number for a given factor,
the more weight that factor will be given when calculating the optimum part orientation. For example,
if build time is most important to you, move the crosshairs closer to the vertex of the prioritization
triangle that is marked with a stopwatch. The composition of the Combined Current Settings orient-
ation map will dynamically adjust to reflect your priorities as you move the crosshairs around in the
triangle.

4. Drag the crosshairs, or use the numeric input fields, in the Combined Current Settings orientation
map to orient the part. You may want to drag the crosshairs to the darkest green position in the
map as this represents the optimum positioning given your priorities. There may be several locations
on the map with the same dark green color. This means that several orientations are considered
optimal. While you are moving the crosshairs around in the map, you will see the part dynamically
rotating in the design window.

Often in an orientation map you will see a distinct, straight line of color change. This is usually a demarc-
ation pertaining to the Overhang Angle (p. 25). In this example, two identical half sphere parts with
slightly different orientations are shown in the figure. The Overhang Angle is 45°. One part (on the left)
is oriented in the near optimum zone to the left of the X=135° line and very few supports are required
to hold the part. The other part (on the right) is oriented just past X=135° which is into the zone not
recommended for volume of supports. As you can see, there are many more supports required to hold
the part to the baseplate.

Have some fun and play around with the orientation map controls! See the effect of changing the
weightings in the prioritization triangle. Explore different part orientations. Try to get an intuitive feel

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 Orienting a Part

for how the part rotates by dragging the crosshairs along different axis lines in the Combined Current
Settings orientation map.

Note:

The orientation maps are calculated dynamically. As such, the maps themselves are not saved
to an .scdoc file and must be calculated again if you close out of SpaceClaim and then reopen
the application. Of course the orientation of your part is saved on the .scdoc file and that is
the important thing.

Orienting a Part — Guidelines and Troubleshooting

• Long time to calculate orientation maps

If it is taking a long time to calculate the orientation maps, you can still orient the part and
continue your workflow without the maps. Alternatively, to speed up orientation if you have a
large, complex model, you can lower the tessellation resolution (p. 180) to "low" in Additive Prep
options. Tessellation resolution has an impact on orientation map generation. But you will want
to reset the resolution before generating supports. You will need to restart each time you change
options.

• An all-green orientation map

On rare occasions, you may see an all-green map for one or more of the orientation maps. This
indicates an invalid map that is just a temporary condition. Simply close the orientation map
panel (by clicking the Orientation Map button in the ribbon) and then open it again.

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Chapter 4: Create Support Regions

Support regions are the means by which supports are created. These regions can be automatically
generated or created manually. Support regions may be created for surfaces and for edges (lines) of
the part body. The triangular facets of the tessellated part are 1) used in the calculation of automatic
support regions, and 2) selected by you for manual creation of support regions. Thus there is a relation-
ship between the resolution of the tessellation and the size and quantity of the support regions. Note
that you can change tessellation resolution options (p. 180) for your non-faceted parts in Additive Prep's
startup options. If you imported an .stl file, the application does not change the faceting.

Manual creation of supports for design bodies is not available at this release.

For automatic support regions, the parameters Overhang Angle, Region Size, and Line Regions establish
the criteria for determining where support regions are created.

Overhang Angle: Angle measured from the horizontal baseplate (0 degrees) to the surface of the part.
Any surface or edge with an angle measuring less than the Overhang Angle will be supported. As an
example, an Overhang Angle of 50° will result in a greater volume of supports than an Overhang Angle
of 40° for the same part. Note that the number of support regions—and correspondingly, supports—is
not necessarily proportional to the resulting volume of supports. It is the total surface area of the support
regions that counts when determining the volume of supports. So, using our example, it is possible to
have fewer support regions/supports with an Overhang Angle of 50° compared to 40° for the given
part but the total volume of supports will be greater with the 50° Overhang Angle.

You may be wondering why you need to specify Overhang Angle again when you set it once already
in the Create Build Volume (p. 5) step. Overhang Angle there was used in the calculation of volume
of supports for determining the orientation maps. Now in the Create Support Regions step you have
an opportunity to change it, if desired, when calculating support regions, which directly affect the
supports generated.

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Create Support Regions

Region Size: Minimum area size, in mm2, for the generation of supports. Surfaces that are smaller than
the defined value will not be considered regardless of their overhang angle and will not have supports
generated for them.

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 Creating Support Regions

Line Regions: This is an option to enable or disable the creation of line support regions at the edges
of a geometric body (subject to the Overhang Angle criteria).

4.1. Creating Support Regions

Automatic Support Regions

To create automatic support regions:

1. Select the Workspace (or any of the components in the workspace assembly) and then click
Create Regions.

2. Adjust the Overhang Angle and Region Size criteria in the Create Regions panel on the right
side of the interface. Check the Line Regions check box to have support regions created at
edges of your part.

3. Click the green check box to create the support regions. Depending on the complexity of
the part, you may see a status window showing the progress of the faceting operation. You
will then see new Support Region objects added under the Support Regions component in the
Structure tree—surface support regions on surfaces and line support regions on edges.

4. To make changes, simply adjust the criteria in the panel and check the green check box again
. Click OK on the confirmation window to clear existing regions (and their supports, if any)
and new support regions are created.

Manual Support Regions

To create manual support regions for faceted .stl parts only:

1. Select the Workspace (or any of the components in the workspace assembly) and then click Create
Regions.

2. Click the Manual Region icon to enable selection of individual facets. Use Ctrl click to select
multiple facets. To change to another means of selection, such as box selection, lasso, paint, etc.,
click the Selection Type tool in the status bar at the bottom of the interface window.

3. Click the green check box to create the manual support regions. Depending on the complexity
of the part, you may see a status window showing the progress of the faceting operation. You will
then see new manual Support Region objects added under the Support Regions component in the
Structure tree—surface support regions on surfaces and line support regions on edges.

4. Click Add to Region to add triangles to the existing set, or Remove from Region to remove
triangles from the existing set, as needed, followed by the green check box .

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Create Support Regions

4.2. Editing Support Regions

You can edit individual facets of any support region, whether it was created automatically or manually.

Use the Add to Region tool or the Remove from Region tool followed by the green check box
to add or remove triangles from any existing support region. If one or more supports are already
associated with that region, however, they will remain intact even after the support region has been
edited. You need to create a new support after the change of the region and delete the old support.

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 Deleting Support Regions

Known Issues and Limitations

There is a known issue at this release in that adding and/or removing triangular facets to manual support
regions (p. 27) does not work as expected. The workaround is to first generate an automatic support
region (p. 27) on the surface where you want manual support regions. Then delete the automatically
created support region and create manual support regions for that surface as described. This time, you
will be able to add/remove individual triangular facets to the manual regions.

4.3. Deleting Support Regions

To delete support regions, select the support region objects in the Structure tree, right-click and select
Delete. The selected support regions and any associated supports are deleted.

Note that support regions and supports are automatically deleted as soon as you perform any of the
following actions:

• Reorient your part using the orientation map

• Modify the Z-Offset (distance between the part and the baseplate)

• Re-create support regions with different regions settings

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Chapter 5: Generate Supports

In this step, you will select individual support regions, choose from a selection of support types, set the
associated parameters, and then generate the supports. For all but custom supports, the resulting
supports will not be watertight volumes. Rather, they will be thin-walled "volumeless" structures intending
to make support removal easier and minimize material while still serving their primary function of
holding the part to the baseplate during manufacture.

5.1. Support Types

Support types for surface support regions include block, adaptive cell, rod, tree, and contour. Block,
adaptive cell, and rod types are made up of interior walls that may or may not have a perimeter contour
wall around them. Tree supports do not have contours. A contour support type is only a contour wall
around the perimeter, with no interior walls.

Support types for line support regions are called line supports.

Figures of the support types are shown next. For these figures we've used our simple half sphere faceted
part (.stl file) and oriented it in different ways to produce various support regions for demonstration.

Block Support
Block supports are grid-shaped supports consisting of regularly arranged rectangles or squares. The
size of the rectangles or squares can be changed. Block supports are available for surface support regions
only. See Parameters for Block Supports (p. 49).

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Generate Supports

Adaptive Cell Support

Adaptive cell supports are arranged in a cubic pattern where the size of the cells reduce in defined in-
tervals from the baseplate towards the part. The size of the cells can be reduced further via a cross-
shaped wall within the cell. Adaptive cell supports are also distinguished by the attachments that connect
the support cells to the part at the upper section of the support walls. Adaptive cell supports are
available for surface support regions only. See Parameters for Adaptive Cell Supports (p. 59).

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 Support Types

Line Support
Line supports are thin walls along the center of the edge to be supported. Each wall is usually crossed
by several supporting walls in the transition area to the baseplate, forming struts. Line supports are
available for line support regions only. See Parameters for Line Supports (p. 67).

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Generate Supports

Rod Support
Rod supports are bar-shaped supports that are distributed in different ways along the area to be sup-
ported, depending on the settings. Rod supports are available for surface support regions only. See
Parameters for Rod Supports (p. 72).

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 Support Types

Tree Support
Tree supports are tree-shaped supports. The lower part of the tree support represents the trunk and
the upper part of the tree support represents the branches of a tree. Tree supports don't use as much
powder as the other support types and are especially useful for supporting the insides of holes. Tree
supports are available for surface support regions only. See Parameters for Tree Supports (p. 83).

Contour Support
A Contour support is a support wall around the perimeter of the support region only. There are no in-
terior walls. See Parameters for Contour-only Supports (p. 93).

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Generate Supports

Custom Support
The Custom Support button on the Create Support panel acts quite differently than the other support
type buttons. Clicking on Custom Support activates the Design tools in SpaceClaim so that you can
create your own support as a solid body. The advantage is that you can have both volumeless supports
and solid support structures in the same file for export.

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 Generating Supports

5.2. Generating Supports

To generate supports (after support regions (p. 25) have been created):

1. Select the Create Support option in the ribbon. The Create Support panel appears in the right
side of the UI, as shown in the following figure.

2. Select one or more SupportRegion objects in the Structure tree for which you want supports
to be generated. You may generate supports for several regions at one time provided they are
the same kind of support region, either surface support regions or line support regions.

3. Select the support type from the Create Support panel. Notice that your selections are filtered.
You can select only support types appropriate for surface regions if you have surface regions
selected, and only line supports if you have line support regions selected.

4. Adjust support parameters as desired. Parameters are further filtered into commonly-used or
expert options. The expert options are more obscure parameters for experienced users. Click

the Detailed View toggle button on or off to show or hide the expert parameters.
This Detailed View toggle button is a "sticky" setting, that is, the application will open the next
time with the toggle set the way it was set when the application closed.

5. Click the green check box to generate the supports. This operation is very fast. If your part
is particularly large and complex, however, it may take a few minutes for the supports to be
generated. You will see new support objects added under the Supports component in the
Structure tree.

One support of each type is allowed per appropriate support region. For example, a surface
support region may have one block, one adaptive cell, one rod, one tree, and one contour
support associated with it.

6. To make changes to supports, simply adjust the parameters in the panel and click the green
check box again and new supports are generated for the selected regions. Any existing
supports of the same type for those regions will be overwritten. For example, changes to block
support parameters overwrite block supports for those regions, adaptive cell parameter changes
overwrite adaptive cell supports, and so on.

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Generate Supports

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 Generating Supports — Guidelines and Troubleshooting

5.3. Generating Supports — Guidelines and Troubleshooting

• To preserve generated supports, do not change the geometry of your part

Because supports and support regions are built upon the lines and surfaces of your part, changing
the geometry of your part, such as with the tools in the Design tab, will invalidate supports and
support regions. If this occurs, you will get a warning and all your supports and support regions
will be deleted.

• "Support could not be created. Check support parameters and try again" message

At times you may receive an error when the application cannot generate supports because of a
problem with parameter settings. Our recommendation is to methodically review your settings
to be sure everything makes sense. Here are two such scenarios:

– You requested adaptive cell supports to be generated but there is not enough space
between the part and the baseplate to create the cells. This happens with the default
adaptive cell parameters when your Z-Offset (p. 19) is 2 mm or less. Your options are to
reduce the Largest Cell Size (p. 60) parameter value or increase the Z-Offset.

– You selected rod supports to be created with only the Min Point Sampler distribution
method (p. 74) selected and your surface support region is a flat surface with no minimum
points in the geometry. You should choose a different distribution method in this case.

• When parts touch the baseplate

If you have a part surface that touches the baseplate (that is, Z-Offset (p. 19) = 0), you may get
tiny supports generated there when you generate supports. By default, support walls intrude,
or penetrate, into the part and baseplate by an intrusion amount. You can control support
parameter intrusion settings as described in the next section. Or, you can delete the support
regions at the baseplate surface if you truly don't want supports in between the part and the
baseplate.

• A region that overlaps on itself in the Z-direction

Avoid having one continuous support region, such as shown below in the coil model on the left,
that overlaps on itself in the Z-direction. Depending on your geometry, this may occur when
creating automatic support regions. When this happens, only a portion of the supports can be
generated using default support parameters. To avoid the problem, create multiple support regions
manually. When selecting facets for any one region, do not include facets that overlap in the Z-
direction.

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Generate Supports

• Artifacts generated from tiny support region facets

On rare occasions you may see what appear to be lines underneath the baseplate after generating
supports. These artifacts are cosmetic only, are from tiny support region facets, and will not be
included in the build file.

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 Changing Support Parameters

5.4. Changing Support Parameters

Parameters are available to control many detailed aspects of the supports, such as the size and spacing
of interior walls, whether they have teeth, perforations, an outer contour, and so on. The parameters
are grouped into tabs in the Create Support panel. General parameters are applicable to all support
types. More specific parameters appear in support-type-specific tabs. The descriptions of the support
parameters provided next are in the order they appear in the panel, including expert parameters. Click

the Detailed View toggle button to see all parameters as you learn about them.
5.4.1. General Parameters
5.4.2. Parameters for Block Supports
5.4.3. Parameters for Adaptive Cell Supports
5.4.4. Parameters for Line Supports
5.4.5. Parameters for Rod Supports
5.4.6. Parameters for Tree Supports
5.4.7. Parameters for Contour-only Supports

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Generate Supports

5.4.1. General Parameters

For any of the predefined support types, general parameters allow you to control:

• Smoothing of edges of the support walls

• Whether to force the support to build to the baseplate

• Whether the supports are angled away from the part to avoid part-to-part supports

• Rotation of supports relative to the gas flow direction

Smooth the Support Edges

Support regions are calculated based on the triangular facets. Every facet is examined with respect
to Overhang Angle and Region Size. Therefore support regions usually have sharp edges due to triangle
corners. Since supports are generated straight down from the regions, rough edges of support walls
are likely. This option allows you to achieve some smoothing of the support edges.

Smooth the Support Edges. If enabled, the sharp edges of the support structure are smoothed
within the bounds of Min Support Angle and Max Support Angle. If disabled, supports are generated
based solely on support region shapes.

• Min Support Angle: The minimum angle between the part and the baseplate up to which the
supports are generated.

• Max Support Angle: The maximum angle between the part and the baseplate up to which the
supports are generated. This means that you can increase the distance between the smoother
drawn edge and the start of the support surface and therefore reduce the area to be supported.

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 Changing Support Parameters

Following is the half sphere part example with a contour-only support with and without smoothed
edges.

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Generate Supports

Here we've hidden the baseplate and rotated the part for better viewing of the support edges with
various settings.

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 Changing Support Parameters

Force to Baseplate

Force build support to baseplate. If enabled, supports will be forced to build to the baseplate.
We recommend you enable this option when you use angled supports.

Known Limitation

Using angled supports from one surface of the part to another is currently not available, especially
if the lower part surface is curved (non-flat). In such a case the part-to-part support fails to compute
a valid attachment to the lower part surface. This is why we recommend enabling the Force build
support to baseplate setting.

Angle the Supports to Avoid Part-to-Part Supports

Use Angled Support. If enabled, supports will be angled away from part features using distance
criteria defined by Upper Plane Z, Lower Plane Z, and Baseplate Translation in the X and Y-directions.
This is done to avoid having supports run into lower portions of the part.

• Upper Plane Z: The distance between the baseplate and the top end of the angled area of the
support, in millimeters.

• Lower Plane Z: The distance between the baseplate and the bottom end of the angled area of
the support, in millimeters.

• Baseplate Translation X: The offset of the lower area of the support relative to the upper area
of the support in the X-direction, in millimeters.

• Baseplate Translation Y: The offset of the lower area of the support relative to the upper area
of the support in the Y-direction, in millimeters.

The supports will not be angled if the Baseplate Translation values are both zero, regardless of the
values of Upper Plane Z and Lower Plane Z.

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Generate Supports

Angled Supports Shortcut

For all support types that allow angled supports, there is a convenient shortcut tool that allows you
to drag guide planes up and down to define the Upper Plane Z and Lower Plane Z parameters.
Dragging the planes in 3D view automatically adjusts the corresponding input fields. Also, toggling
on the shortcut button automatically enables the Use Angled Support check box.

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 Changing Support Parameters

Rotate Supports Relative to the Gas Flow Direction

Rotate Support. If enabled, supports will be aligned relative to the gas flow direction according
to Rel. Gas Flow Angle.

• Rel. Gas Flow Angle: The angle for the rotation of the supports, in degrees. An angle of 0° means
that the supports are aligned in the direction of the gas flow.

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Generate Supports

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 Changing Support Parameters

5.4.2. Parameters for Block Supports

In addition to the general support parameters (p. 42), parameters specific to block supports allow
you to control:

• Spacing and translation of the cells

• How far the supports intrude into the part

• Tooth-shaped cutouts at the upper and lower edges of supports

• Perforations in the support walls

• Clearance between vertical walls of the part and the supports

Spacing and Translation of Cells

X Spacing: The size of the block cells in the X-direction, in millimeters.

Y Spacing: The size of the block cells in the Y-direction, in millimeters.

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Generate Supports

X Shift: The translation of the block cells in the X-direction, in millimeters.

Y Shift: The translation of the block cells in the Y-direction, in millimeters.

Intrusion into Part

It is common practice for supports to intrude, or penetrate, into part geometry. This ensures a good
connection between the part and the support.

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 Changing Support Parameters

Intrusion Top: The distance the top of the interior support walls penetrate into the part, in millimeters.

Intrusion Bottom: The distance the bottom of the interior support walls penetrate into the part (for
part-to-part supports), in millimeters.

Tooth Pattern
Tooth patterns are tooth-shaped cut-outs at the upper and/or lower edges of each support wall. They
can be generated between a part and the baseplate or between part areas. Their main purpose is to
make it easier to remove supports.

Create Top Tooth Pattern: If enabled, cut-outs are generated at the upper edge of the interior
support walls in the form of teeth. This is at the connection between the support walls and the un-
derlying part surface.

• Top Tooth Bottom Width: The lower width of each tooth, in millimeters.

• Top Tooth Crossing Width: The distance between the end of the top width and the start of the
lower width, in millimeters. This affects the distance between teeth.

• Top Tooth Width: The upper width of each tooth, in millimeters. A value of zero will produce
a pointed tooth at the top, subject to intrusion settings.

• Top Tooth Height: The height of the top tooth, in millimeters.

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Generate Supports

Create Bottom Tooth Pattern: If enabled, cut-outs are generated at the lower edge of the
interior support walls in the form of teeth. This is at the connection between the support walls and
the baseplate (or lower part surface).

• Bottom Tooth Bottom Width: The lower width of each tooth, in millimeters. A value of zero will
produce a pointed tooth at the intersection of the support walls and the baseplate (or lower
part), subject to intrusion settings.

• Bottom Tooth Crossing Width: The distance between the end of the top width and the start of
the lower width, in millimeters. This affects the distance between teeth.

• Bottom Tooth Top Width: The upper width of each tooth, in millimeters.

• Bottom Tooth Height: The height of the bottom tooth, in millimeters.

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Perforate the Support Walls

Here you can define settings for perforations in interior block support walls.

Perforate the support walls: If enabled, perforations are generated.

• Type: The shape of the perforations. A simple diamond is the only shape available.

• Width: The width of the diamond, in millimeters.

• Height: The height of the diamond, in millimeters.

• Height Clearance: The distance between the diamonds in height—the height interval, in milli-
meters.

• Width Clearance: The distance between the diamonds in width—the width interval, in milli-
meters.

• Top Solid Height: The distance between the uppermost diamonds and the part at the top of
the support wall, in millimeters.

• Bottom Solid Height: The distance between the lowermost diamonds and the baseplate (or
lower part) at the bottom of the support wall, in millimeters.

• Alternate diamonds: If enabled, the diamonds will be positioned offset to each other.

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Check Part Clearance

Check Part Clearance: If enabled, you can define parameters for the minimum distance
between a vertical wall and supports. This avoids the collision of parts and supports.

• Clearance: The minimum distance between a vertical wall of the part and the support walls,
in millimeters.

• Collision Volume Vertical Offset: The vertical distance from a part surface in which the part
clearance function is not applied, in millimeters. This creates a fictitious wall between the part
and the area in which the part clearance function is applied.

• Collision Volume Inclination: The angle of the fictitious wall from which the part clearance
function is not applied, in degrees.

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5.4.2.1. Parameters for Block Supports (Contour)

Build a contour around the support region: If enabled, the interior block support walls are
reinforced with a contour on the outermost perimeter of the support surface. If disabled, all the
parameters in the ContourParams tab are unavailable.

Intrusion into Part

Top Intrusion Contour: The distance the top of the contour support wall penetrates into the
part, in millimeters.

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Bottom Intrusion Contour: The distance the bottom of the contour support wall penetrates
into the part (for part-to-part supports), in millimeters.

Check Part Clearance

Part Clearance: The distance between the contour support wall and a vertical wall of the part,
in millimeters.

Offset Contour: The distance the contour support wall will be offset from the outer edge of
the support region, in millimeters.

Tooth Pattern
Tooth patterns are tooth-shaped cut-outs at the upper and/or lower edges of each support. They
can be generated between a part and the baseplate or between part areas. Their main purpose is
to make it easier to remove supports.

Create Top Tooth Pattern on Contour: If enabled, cut-outs are generated at the upper edge
of the contour support wall in the form of teeth. This is at the connection between the contour
support wall and the underlying part surface.

• Tooth Bottom Width (Contour): The lower width of each tooth, in millimeters.

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• Tooth Crossing Width (Contour): The distance between the end of the top width and the
start of the lower width, in millimeters. This affects the distance between teeth.

• Tooth Top Width (Contour): The upper width of each tooth, in millimeters. A value of
zero will produce a pointed tooth at the top, subject to intrusion settings.

• Tooth Height (Contour): The height of the top tooth, in millimeters.

Create Bottom Tooth Pattern on Contour: If enabled, cut-outs are generated at the lower
edge of the contour support wall in the form of teeth. This is at the connection between the contour
support wall and the baseplate (or lower part surface).

• Tooth Bottom Width (Contour): The lower width of each tooth, in millimeters. A value of
zero will produce a pointed tooth at the intersection of the contour support wall and the
baseplate (or lower part), subject to intrusion settings.

• Tooth Crossing Width (Contour): The distance between the end of the top width and the
start of the lower width, in millimeters. This affects the distance between teeth.

• Tooth Top Width (Contour): The upper width of each tooth, in millimeters.

• Tooth Height (Contour): The height of the bottom tooth, in millimeters.

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Perforate the Contour

Here you can define settings for perforations in the contour support wall.

Perforate the support walls: If enabled, perforations are generated.

• Type: The shape of the perforations. A simple diamond is the only shape available.

• Width (Contour): The width of the diamond, in millimeters.

• Height (Contour): The height of the diamond, in millimeters.

• Height Clearance (Contour): The distance between the diamonds in height—the height
interval, in millimeters.

• Width Clearance (Contour): The distance between the diamonds in width—the width
interval, in millimeters.

• Top Solid Height (Contour): The distance between the uppermost diamonds and the part
at the top of the support wall, in millimeters.

• Bottom Solid Height (Contour): The distance between the lowermost diamonds and the
baseplate (or lower part) at the bottom of the support wall, in millimeters.

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• Alternate diamonds (Contour): If enabled, the diamonds will be positioned offset

to each other.

5.4.3. Parameters for Adaptive Cell Supports

In addition to the general support parameters (p. 42), parameters specific to adaptive cell supports
allow you to control:

• The adaptive cell shape (type); either default, cross attachment, or full attachment

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• The size and number of subdivisions of the cells

• Whether the supports extend over the border of the part

• Clearance between the part and the supports

• How far the supports intrude into the part

• Tooth-shaped cutouts at the upper edges of supports

• Whether to force part-to-part supports

Adaptive Cell Type

Adaptive Cell Type: The shape of the adaptive cell supports at the top of the support walls near the
attachments. Types include:

• Default: Cross-rods will be built at each intersection of cell walls.

• Cross Attachment: Cross-rods will be built at each intersection of cell walls, except the middle.

• Full Attachment: The walls of the uppermost cell will be extended into the part, according
to the attachment intrusion parameter.

The following options and defaults are the same for all adaptive cell types.

Size and Subdivisions of Cells

Largest Cell Size: The largest cell size (the lowest level shown in the figure), in millimeters.

Max Subdivisions: A number defining how frequently the horizontal adaptive cell cells may be reduced
in size. For example, a value of 3 will generate a maximum total of four levels as shown in the figure.

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Extend Over the Border

Extend Over Border: If enabled, the supports in the X and Y-direction may extend past the
edge of the support surface. This means that the supports may be wider than the part in some cases.

Max Subdivisions Border: The maximum number of reductions in adaptive cells in the area of the
contour for the support.

Min Subdivisions Border: The minimum number of reductions in adaptive cells in the area of the contour
for the support.

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Smallest Cell Inwards: The depth of the adaptive cells (based on the values under Max Subdivisions
Border and Min Subdivisions Border), in millimeters.

Check Part Clearance

Smallest Cells for Clearance: The size of the smallest adaptive cells for clearance from a vertical
wall of a part, in millimeters.

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 Changing Support Parameters

Number of Smallest Cells

Min Number Smallest Cells: The minimum number of smallest adaptive cells in the vertical direction.

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Attachments
Because only complete adaptive cells are generated, gaps may occur between the supports and the
part. Attachments are used to close any gaps.

Attachment Intrusion: The distance the attachments penetrate into the part, in millimeters.

Min Attachment Height: The minimum length of attachments, in millimeters.

Max Attachment Height: The maximum length of attachments, in millimeters.

Build a Contour Around Support

Build contour: If enabled, the adaptive cell support walls are reinforced with a contour on the
outermost perimeter of the support surface.

Top Intrusion (contour): The distance the top of the contour support wall penetrates into the part,
in millimeters.

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Min Segment Length for Opening (contour): The minimum length of an adaptive cell from which
a contour is generated from this adaptive cell, in millimeters.

Opening Distance from Cell Top (contour): The distance between the uppermost end of the contour
and the upper end of an adaptive cell, in millimeters.

Create Top Tooth Pattern (contour): If enabled, cut-outs are generated at the upper edge
of the support in the form of teeth. The cutouts are generated only in the contour and not in the
support itself for adaptive cell supports.

• Bottom Width: The lower width of each tooth, in millimeters.

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• Crossing Width: The distance between the end of the top width and the start of the lower width,
in millimeters. This affects the distance between teeth.

• Top Width: The upper width of each tooth, in millimeters. A value of zero will produce a pointed
tooth at the top, subject to intrusion settings.

• Height : The height of the top tooth, in millimeters.

Part-to-Part Support

Do part-to-part support: If enabled, supports can also be generated between part areas as
well as between the part and the baseplate.

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5.4.4. Parameters for Line Supports

In addition to the general support parameters (p. 42), parameters specific to line supports allow you
to control:

• Tooth-shaped cutouts at the upper edges of supports

• Perforations in the support walls

• How far the supports intrude into the part

• Struts in the support walls

Tooth Pattern
Tooth patterns are tooth-shaped cut-outs at the upper and/or lower edges of each support wall. They
can be generated between a part and the baseplate or between part areas. Their main purpose is to
make it easier to remove supports.

Create Top Tooth Pattern: If enabled, cut-outs are generated at the upper edge of the
support walls in the form of teeth. This is at the connection between the support walls and the un-
derlying part surface.

• Bottom Width: The lower width of each tooth, in millimeters.

• Crossing Width: The distance between the end of the top width and the start of the lower
width, in millimeters. This affects the distance between teeth.

• Top Width: The upper width of each tooth, in millimeters. A value of zero will produce a pointed
tooth at the top, subject to intrusion settings.

• Height: The height of the top tooth, in millimeters.

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Create Bottom Tooth Pattern: If enabled, cut-outs are generated at the lower edge of the
support walls in the form of teeth. This is at the connection between the support walls and the
baseplate (or lower part surface).

• Bottom Width: The lower width of each tooth, in millimeters. A value of zero will produce a
pointed tooth at the intersection of the support walls and the baseplate (or lower part), subject
to intrusion settings.

• Crossing Width: The distance between the end of the top width and the start of the lower
width, in millimeters. This affects the distance between teeth.

• Top Width: The upper width of each tooth, in millimeters.

• Height: The height of the bottom tooth, in millimeters.

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Perforate Support Walls

Here you can define settings for perforations in line support walls. Settings for the perforations are
applied to both the external contour (if being generated) and the internal line support walls.

Perforate the support walls: If enabled, perforations are generated.

• Type: The shape of the perforations. A simple diamond shape is available.

• Width: The width of the diamond, in millimeters.

• Height: The height of the diamond, in millimeters.

• Height Clearance: The distance between the diamonds in height – the height interval, in
millimeters.

• Width Clearance: The distance between the diamonds in width – the width interval, in
millimeters.

• Top Solid Height: The distance between the uppermost diamonds and the part at the top
of the support wall, in millimeters.

• Bottom Solid Height: The distance between the lowest diamonds and the baseplate (or
lower part) at the bottom of the support wall, in millimeters.

• Alternate diamonds: If enabled, the diamonds will be positioned offset to each other.

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Intrusion into Part

Intrusion Top: The distance the top of the support walls penetrate into the part, in millimeters.

Intrusion Bottom: The distance the bottom of the support walls penetrate into the part (for
part-to-part supports), in millimeters.

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Include Struts

Line has Struts: If enabled, struts are generated.

• Struts Distance: The distance between the individual struts, in millimeters.

• Strut Min Height: The height of the struts, in millimeters. Struts that are smaller than the defined
value are not generated.

• Strut Min Top Distance: The minimum distance between the uppermost end of the strut and
the part, in millimeters.

• Strut Max Top Distance: The maximum distance between the uppermost end of the strut and
the part, in millimeters.

• Strut Base Height: The height of the strut up to which the struts run upwards at a 90° angle to
the baseplate, in millimeters. After this height, the struts buckle and point directly upwards.

• Strut Half Min Width: The minimum width of the strut halves on the baseplate, in millimeters.

• Strut Max Width: The maximum width of the struts on the baseplate, in millimeters.

• Strut Mesh Clearance: The distance between the struts and a nearby part surface, in millimeters.

• Strut Max Slope on Part: The angle up to which struts are generated, in degrees.

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5.4.5. Parameters for Rod Supports

In addition to the general support parameters (p. 42), parameters specific to rod supports allow you
to control:

• The rod shape (type), either cross rod, octagonrod, perf tube, round rod, or X rod

• The rod diameter

• Clearance between the part and the supports

• The rod distribution, that is, the placement and spacing of rods as determined by several
possible sampling techniques that each have their own settings

• Characteristics of the tip and base of the rod, including intrusion

Rod Type
Rod Type: The shape, or form, of the rods for the rod support. Types are shown in the following figure.

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Rod Diameter
Rod Diameter: The diameter of the individual rods, in millimeters.

Part Clearance

Check Part Clearance: If enabled, you can define parameters for the minimum distance
between a vertical wall and supports. This avoids the collision of parts and supports.

• Clearance: The minimum distance between a vertical wall of the part and the support walls,
in millimeters.

• Collision Volume Vertical Offset: The vertical distance from a part surface in which the part
clearance function is not applied, in millimeters. This creates a fictitious wall between the part
and the area in which the part clearance function is applied.

• Collision Volume Inclination: The angle of the fictitious wall from which the part clearance
function is not applied, in degrees.

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Rod Distribution
The spacing and pattern of how rods are distributed under a surface region are determined by one
or more sampling selections.

Use Min Point Sampler: If enabled, rod supports are generated in a local minimum of a surface
to be supported. This prevents geometries from being created loose in the powder.

• Min Distance to Outer Perimeter: The minimum distance between the rod supports and the
outer perimeter of the support region, in millimetres. (Note: This feature applies even if a
contour wall is disabled.)

• Local Domain Size Distance: The diameter of a local minimum in which no other minimum
should be searched for, in millimeters. The diameter is shown as light blue circles in the figures
below.

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Use Contour Sampler: If enabled, rod supports are generated along the edges of the surface to
be supported.

• Min Distance to Outer Perimeter: The minimum distance between the rod supports and the
outer perimeter of the support region, in millimetres. (Note: This feature applies even if a
contour wall is disabled.)

• Min Distance Between Points: The minimum distance between the individual rods of the
rod support, in millimeters.

Use Regular Grid Sampler: If enabled, rods for the rod support are generated at regular intervals
for the selected surface to be supported. In doing this, a fictitious cell is created for each rod of the
rod support and the size of this cell can be changed. In this way, you can define the minimum distance
between the rods.

• Min Distance to Outer Perimeter: The minimum distance between the rod supports and the
outer perimeter of the support region, in millimetres. (Note: This feature applies even if a
contour wall is disabled.)

• Grid Cell Size X: The width of the fictitious cell in the X-direction, in millimeters.

• Grid Cell Size Y: The width of the fictitious cell in the Y-direction, in millimeters.

Use Poisson Disk Sampler: If enabled, rod supports are generated and distributed for the surface
to be supported based on a statistical Poisson distribution.

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• Min Distance to Outer Perimeter: The minimum distance between the rod supports and the
outer perimeter of the support region, in millimetres. (Note: This feature applies even if a
contour wall is disabled.)

• Min Distance Between Points: The minimum distance between the individual rods of the
rod support, in millimeters.

• Seed: The starting point for the random generator for the Poisson sampling distribution.
If 0, the distribution is random for each regeneration of the rod support. If Seed is set to a
specific number >0, the rod distribution is deterministic and therefore reproducible. A negative
Seed value is not valid.

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Tip and Base of Rod

Tip Height: The height of the tip of the rod, in millimeters.

Tip Scale: The scale (proportion) of the tip of the rod relative to the rod diameter. For example,
if Rod Diameter is 0.8 mm and Tip Scale is 0.5, then the tip diameter will be 0.4 mm, which is half of
the rod diameter.

Tip Intrusion: The distance the top of the support rods penetrate into the part, in millimeters. This
intrusion length is not included in Tip Height, rather, it is an extra distance added above the tip height.

Tip Max Extension Height: The distance within which the tip of the rod will attach itself to a
mesh on both the inside and outside of an edge, chamfer, or step, in millimeters. Depending on
geometry, you may need to increase the Max Extension Height to ensure attachment to a step or
chamfer.

Base Height: The height of the base of the rod, in millimeters.

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Base Scale: The scale (proportion) of the base of the rod relative to the rod diameter. For example,
if Rod Diameter is 0.8 mm and Base Scale is 0.5, then the base diameter will be 0.4 mm, which is half
of the rod diameter.

Base Intrusion: The distance the bottom of the support rods penetrate into the part (for part-to-part
supports), in millimeters.

Base Max Extension Height: The distance within which the base of the rod will attach itself to
a mesh on both the inside and outside of an edge, chamfer, or step, in millimeters. Depending on
geometry, you may need to increase the Max Extension Height to ensure attachment to a step or
chamfer.

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 Changing Support Parameters

5.4.5.1. Parameters for Rod Supports (Contour)

Build a contour around the support region: If enabled, the interior rod support walls are re-
inforced with a contour on the outermost perimeter of the support surface. If disabled, all the
parameters in the ContourParams tab are unavailable.

Intrusion into Part

Top Intrusion Contour: The distance the top of the contour support penetrates into the part,
in millimeters.

Bottom Intrusion Contour: The distance the bottom of the contour support wall penetrates
into the part (for part-to-part supports), in millimeters.

Check Part Clearance

Part Clearance: The distance between the contour support wall and a vertical wall of the part,
in millimeters.

Offset Contour: The distance the contour support wall will be offset from the outer edge of
the support region, in millimeters.

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Tooth Pattern
Tooth patterns are tooth-shaped cut-outs at the upper and/or lower edges of each support. They
can be generated between a part and the baseplate or between part areas. Their main purpose is
to make it easier to remove supports.

Create Top Tooth Pattern on Contour: If enabled, cut-outs are generated at the upper edge
of the contour support wall in the form of teeth. This is at the connection between the contour
support wall and the underlying part surface.

• Tooth Bottom Width (Contour): The lower width of each tooth, in millimeters.

• Tooth Crossing Width (Contour): The distance between the end of the top width and the
start of the lower width, in millimeters. This affects the distance between teeth.

• Tooth Top Width (Contour): The upper width of each tooth, in millimeters. A value of
zero will produce a pointed tooth at the top, subject to intrusion settings.

• Tooth Height (Contour): The height of the top tooth, in millimeters.

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Create Bottom Tooth Pattern on Contour: If enabled, cut-outs are generated at the lower
edge of the contour support wall in the form of teeth. This is at the connection between the contour
support wall and the baseplate (or lower part surface).

• Tooth Bottom Width (Contour): The lower width of each tooth, in millimeters. A value of
zero will produce a pointed tooth at the intersection of the contour support wall and the
baseplate (or lower part), subject to intrusion settings.

• Tooth Crossing Width (Contour): The distance between the end of the top width and the
start of the lower width, in millimeters. This affects the distance between teeth.

• Tooth Top Width (Contour): The upper width of each tooth, in millimeters.

• Tooth Height (Contour): The height of the bottom tooth, in millimeters.

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Perforate the Contour

Here you can define settings for perforations in the contour support wall.

Perforate the support walls: If enabled, perforations are generated.

• Type: The shape of the perforations. A simple diamond is the only shape available.

• Width (Contour): The width of the diamond, in millimeters.

• Height (Contour): The height of the diamond, in millimeters.

• Height Clearance (Contour): The distance between the diamonds in height—the height
interval, in millimeters.

• Width Clearance (Contour): The distance between the diamonds in width—the width
interval, in millimeters.

• Top Solid Height (Contour): The distance between the uppermost diamonds and the part
at the top of the support wall, in millimeters.

• Bottom Solid Height (Contour): The distance between the lowermost diamonds and the
baseplate (or lower part) at the bottom of the support wall, in millimeters.

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 Changing Support Parameters

• Alternate diamonds (Contour): If enabled, the diamonds will be positioned offset

to each other.

5.4.6. Parameters for Tree Supports

In addition to the general support parameters (p. 42), parameters specific to tree supports allow you
to control:

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• How the tree supports are generated, with trunks extending either toward the baseplate or
toward the part

• Characteristics of the uppermost branch tips that attach to the part (attachments), such as
length and intrusion settings

• The branch distribution across the support region, that is, the placement and spacing of branch
tips as determined by several possible sampling techniques that each have their own settings

Note that there are no perforations or tooth patterns for tree supports and the ability to angle tree
supports is not available.

Angle of the Tree Branches

The generation of tree supports begins with a point sampling distribution on the surface region. The
algorithm starts by creating a cone of a certain apex angle, offset by a certain vertical distance, under
each sampling point. A new branch is created wherever cones intersect. In this way, the tree is gen-
erated from the top to the bottom.

Tree Cone Apex Angle: The angle of the cone that is positioned after the offset under each sampling
point. Larger angles result in many small branches at the top of the tree and a heavier trunk at the
bottom. Smaller angles force the branches down to the baseplate such that an angle of 0° results in
every branch reaching the baseplate, like in block supports. After several experiments, we chose a
default angle of 55° for a reasonable amount of stiffness in the tree support structure.

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 Changing Support Parameters

Attachment Vertical Offset: If enabled, each branch tip is offset by a certain amount before the
start of the first cone.

• Attachment Vertical Offset Distance: The length of the vertical offset before the first cone,
in millimeters.

Tips of the Branches

Tip Height: The length of the tip attachment, in millimeters.

Tip Scale: The scale (proportion) of the tip of the branch relative to the branch's top diameter.
For example, if Top Diameter is 0.8 mm and Tip Scale is 0.5, then the tip diameter will be 0.4 mm,
which is half of the top diameter.

Tip Intrusion: The distance the tips of the tree branches penetrate into the part, in millimeters.

Tip Max Extension Height: The distance within which the tip will attach itself to a mesh on both
the inside and outside of an edge, chamfer, or step, in millimeters. Depending on geometry, you may
need to increase the Max Extension Height to ensure attachment to a step or chamfer.

Top Diameter: The diameter of the top of a branch before the tip attachment, in millimeters.

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Weight (Thickness of Branches)

These parameters control the weight and, in effect, the thickening of the tree.

Weight By Length Summand: For a length of 1.0, the weight gets increased by the given factor. If
two branches join, the weight of the longer branch is selected. Set to 0.0 by default to avoid any effect
on the weight.

Weight By Fork Summand: At each fork, the given constant value gets added to the weight. Set to
0.0 by default to avoid any effect on the weight.

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 Changing Support Parameters

Weight By Fork Factor: At each fork, weight of the branch with the lesser weight gets multiplied by
the given factor and is added to the total weight. Set to 1.0 to avoid any effect on the weight.

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Generate Supports

Length (Direction of Growth)

When length parameters are set to their defaults, a tree branch or trunk is built based upon which
possible connection has the shortest length. There are three possible types of connections:

• Branch to another cone/branch

• Connect/attach to the part

• Build down to the baseplate

You can drive the support generation algorithm by changing these connection lengths. Set the
parameters such that the connections you do not want (for example, part-to-part supports) have the
longest lengths. Factor and summand parameters work together to influence the direction of tree
growth, either toward the part or toward the baseplate, and indirectly, how many tree branches there
will be. Think of the set of factor parameters as the first level of control and the summand parameters
as a finer level of control. Adjust the factors first and then generate the supports to see what the tree
structure looks like. If you're not satisfied, adjust the summand parameters.

For better control, each length is multiplied by one of the factors. This way you can, for example, set
a strong bias to avoid connections to the part. Set all factors to 1.0 for no effect (default).

Branch Length Factor: Multiplication factor for a connection to another branch intersection point.

Tree-to-Mesh (Part) Length Factor: Multiplication factor for a connection to the part.

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 Changing Support Parameters

Tree-to-Baseplate Length Factor: Multiplication factor for a connection to the baseplate.

Similar to the factors, the summands are constants that are added to each connection type. Set them
to 0 for no effect (default).

Branch Length Summand: Value is added to the length of a connection to another branch intersection
point.

Tree-to-Mesh (Part) Length Summand: Value is added to the length of a connection to the part.

Tree-to-Baseplate Length Summand: Value is added to the length of a connection to the baseplate.

Maximum Attachments Per Trunk

Max Attachments Per Trunk: The maximum number of attachments that a single branch/trunk can
support. If the limit is reached, a to-mesh or to-platform branch/trunk is built. A very large value results
in one trunk.

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Generate Supports

Branch Distribution
The spacing and pattern of how branches are distributed under a surface region are determined by
one or more sampling selections. These distribution parameters are exactly the same as the rod
support distribution parameters.

Use Min Point Sampler: If enabled, tree supports are generated in a local minimum of a surface
to be supported. This prevents geometries from being created loose in the powder.

• Min Distance to Outer Perimeter: The minimum distance between the tree supports and
the outer perimeter of the support region, in millimetres. (Note: This feature applies even if a
contour wall is disabled.)

• Local Domain Size Distance: The diameter of a local minimum in which no other minimum
should be searched for, in millimeters. The diameter is shown as light blue circles in the figures
below.

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Use Contour Sampler: If enabled, tree supports are generated along the edges of the surface to
be supported.

• Min Distance to Outer Perimeter: The minimum distance between the tree supports and
the outer perimeter of the support region, in millimetres.

• Min Distance Between Points: The minimum distance between the individual branches of
the tree support, in millimeters.

Use Regular Grid Sampler: If enabled, branches for the tree support are generated at regular
intervals for the selected surface to be supported. In doing this, a fictitious cell is created for each
branch of the tree support and the size of this cell can be changed. In this way, you can define the
minimum distance between the branches.

• Min Distance to Contour: The minimum distance between the tree supports and the outer
perimeter of the support region, in millimetres.

• Grid Cell Size X: The width of the fictitious cell in the X-direction, in millimeters.

• Grid Cell Size Y: The width of the fictitious cell in the Y-direction, in millimeters.

Use Poisson Disk Sampler: If enabled, tree supports are generated and distributed for the surface
to be supported based on a statistical Poisson distribution.

• Min Distance to Outer Perimeter: The minimum distance between the tree supports and
the outer perimeter of the support region, in millimetres.

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Generate Supports

• Min Distance Between Points: The minimum distance between the individual branches of
the tree support, in millimeters.

• Seed: The starting point for the random generator for the Poisson sampling distribution.
If 0, the distribution is random for each regeneration of the tree support. If Seed is set to a
specific number >0, the branch distribution is deterministic and therefore reproducible. A
negative Seed value is not valid.

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5.4.7. Parameters for Contour-only Supports

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Generate Supports

In addition to the general support parameters (p. 42), parameters specific to contour (only) supports
allow you to control:

• How far the support wall intrudes into the part

• Clearance between the part and the support wall

• Tooth-shaped cutouts at the upper and lower edges of the support wall

• Perforations in the support wall

Build a contour around the support region: If enabled, a contour on the outermost perimeter
of the support region surface is generated.

Intrusion into Part

Top Intrusion Contour: The distance the top of the contour support penetrates into the part,
in millimeters.

Bottom Intrusion Contour: The distance the bottom of the contour support penetrates into the
part (for part-to-part supports), in millimeters.

Check Part Clearance

Part Clearance: The distance between the contour support wall and a vertical wall of the part,
in millimeters.

Offset Contour: The distance the contour support wall will be offset from the outer edge of the
support region, in millimeters.

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Tooth Pattern
Tooth patterns are tooth-shaped cut-outs at the upper and/or lower edges of each support. They can
be generated between a part and the baseplate or between part areas. Their main purpose is to make
it easier to remove supports.

Create Top Tooth Pattern on Contour: If enabled, cut-outs are generated at the upper edge of
the contour support wall in the form of teeth. This is at the connection between the contour support
wall and the underlying part surface.

• Tooth Bottom Width (Contour): The lower width of each tooth, in millimeters.

• Tooth Crossing Width (Contour): The distance between the end of the top width and the
start of the lower width, in millimeters. This affects the distance between teeth.

• Tooth Top Width (Contour): The upper width of each tooth, in millimeters. A value of zero
will produce a pointed tooth at the top, subject to intrusion settings.

• Tooth Height (Contour): The height of the top tooth, in millimeters.

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Generate Supports

Create Bottom Tooth Pattern on Contour: If enabled, cut-outs are generated at the lower edge
of the contour support wall in the form of teeth. This is at the connection between the contour support
wall and the baseplate (or lower part surface).

• Tooth Bottom Width (Contour): The lower width of each tooth, in millimeters. A value of
zero will produce a pointed tooth at the intersection of the contour support wall and the
baseplate (or lower part), subject to intrusion settings.

• Tooth Crossing Width (Contour): The distance between the end of the top width and the
start of the lower width, in millimeters. This affects the distance between teeth.

• Tooth Top Width (Contour): The upper width of each tooth, in millimeters.

• Tooth Height (Contour): The height of the bottom tooth, in millimeters.

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Perforate the Contour

Here you can define settings for perforations in the contour support wall.

Perforate the support walls: If enabled, perforations are generated.

• Type: The shape of the perforations. A simple diamond is the only shape available.

• Width (Contour): The width of the diamond, in millimeters.

• Height (Contour): The height of the diamond, in millimeters.

• Height Clearance (Contour): The distance between the diamonds in height—the height
interval, in millimeters.

• Width Clearance (Contour): The distance between the diamonds in width—the width interval,
in millimeters.

• Top Solid Height (Contour): The distance between the uppermost diamonds and the part
at the top of the support wall, in millimeters.

• Bottom Solid Height (Contour): The distance between the lowermost diamonds and the
baseplate (or lower part) at the bottom of the support wall, in millimeters.

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Generate Supports

• Alternate diamonds (Contour): If enabled, the diamonds will be positioned offset to

each other.

5.5. Deleting Supports

You use the same steps to delete supports as you would any object in the Structure tree. Right-click
the object and select Delete. The selected support objects in the Structure tree are deleted but their
associated support regions are not deleted, nor are the support parameters set back to defaults. Support
parameter settings are associated with the support regions, not the supports.

Note that supports and support regions are automatically deleted as soon as you perform any of the
following actions:

• Reorient your part using the orientation map

• Modify the Z-Offset (distance between the part and the baseplate)

• Re-create support regions with different regions settings

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Chapter 6: Generate a Build File

Once you are satisfied with your part(s) and supports, the next step is to use the Build Processor to
generate a build file. A build file contains the detailed information about the scan pattern that is required
by the 3D printing machine.

Build file options differ depending on your machine. The following topics are available:
6.1. Generating a Build File for SLM Machines
6.2. Generating a Build File for EOS Machines
6.3. Generating a Build File for Renishaw Machines

6.1. Generating a Build File for SLM Machines

To generate an SLM build file:

1. Select the Build Processor option in the ribbon. The Build Processor panel appears in the right
side of the UI, as shown in the following figure.

2. Select a preset build strategy (p. 100) from the drop-down menu under Load a Strategy, or
simply do nothing to use the default strategy.

3. Adjust build process parameters (p. 101) as desired. When you have finished making changes,
click the Assign button to assign the changes to the selected workspace assembly, or click the
Assign All button to apply the changes to all the workspaces in the Build Volume.

4. Click the green check box to generate the build file. It is still an internal file at this point.
(You will need to Export (p. 171) to obtain a file on your computer.) If your part is particularly
large and complex, it may take a few minutes for the build file to be generated. You will see
the message "Open Slice Viewer tool to view build file" when the operation is complete.

5. To make changes, simply adjust the parameters, click Assign or Assign All, and click the green
check box again and a new build file is generated.

6. Next you will probably want to review the build file in the Slice Viewer (p. 163) tool.

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6.1.1. Defining a Build Strategy

A preset collection of scan pattern settings is called a build strategy. Think of a build strategy as a
template. You may choose from one of the many presets available in Additive Prep, or you may
choose the basic default strategy. You can then make changes to the build parameters from there,
and then save your strategy as a new template.

The contents of the build strategy preset is reflected in the preset name. Let's look at an example.
Two strategy file names are shown here:

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A = material, in this case 316L steel

B = method, in this case selective laser melting

C = slice thickness in microns, in this case 30 microns in the first file and 50 microns in the second
file

D = max power, in this case 400 W

E = the hatch pattern, in this case stripes

6.1.2. Changing Build Process Parameters

Parameters are available to control many detailed aspects of the SLM build file, such as scaling, hatch
pattern, slice thickness, up-skin and down-skin parameters, and so on. Parameters are grouped into
tabs in the Build Processor panel.

Each layer of metal powder is arranged into one or more areas (volume, up-skin and down-skin). Each
of these areas is exposed with its own build strategy, each with specific vector types.

The following build process parameter topics are available:

6.1.2.1. Scaling Parameters
6.1.2.2. Slicing Parameters
6.1.2.3. Volume Parameters
6.1.2.4. Up-skin Remelting Parameters
6.1.2.5. Up-skin Recoating Parameters
6.1.2.6. Down-skin Parameters
6.1.2.7. Support Parameters
6.1.2.8. Scanning Parameters

6.1.2.1. Scaling Parameters

Scaling parameters allow you to scale (either reduce or enlarge) parts on the baseplate, usually
used to compensate for shrinkage due to cooling after the build process.

Scale Z: The factor for scaling in the Z-direction.

Scale Y: The factor for scaling in the Y-direction.

Scale X: The factor for scaling in the X-direction.

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Scale Around Center: If enabled, the parts are scaled around the midpoint of the baseplate. This
causes a translation on the X and Y-axes. The fusing of part areas can be avoided through upscaling.
If disabled, each part is scaled around its own midpoint.

6.1.2.2. Slicing Parameters

Slicing takes place before each build process. A part is partitioned into horizontal layers with a
defined layer thickness. Slicing means that the vector types used during the build process are visible
in every layer of metal powder.
6.1.2.2.1. General
6.1.2.2.2. Contour Filter
6.1.2.2.3. Offset

6.1.2.2.1. General
Slice Thickness: The thickness of the individual layers of metal powder.

Slice Height Factor: Identifies where the slice should be within the layer. A value of 0 represents
the lowest area of a layer. A value of 0.5 represents half of the layer and a value of 1 represents
the uppermost area of a layer.

Gap Tolerance: The maximum length of gaps between vectors. Gaps that are shorter than the
defined value are closed automatically.

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Use Limits. If enabled, you can define the Z-dimensions for the part between which the slicing
should take place. This means that only a restricted area of the part is analyzed and time is saved,
useful for test purposes, for example.

• Min Z: The value on the Z-axis at which slicing should start.

• Max Z: The value on the Z-axis at which slicing should stop. If specified, the AM machine
will treat the Max Z layer as an up-skin layer. (The last layer is always an up-skin.)

6.1.2.2.2. Contour Filter

Filter Area: If enabled, areas that are smaller than Min Area are not exposed.

• Min Area: The minimum size of an area for exposure. Areas that are smaller than the defined
value are not exposed.

Filter Length: If enabled, areas that have a shorter external contour than Min Length are
not exposed.

• Min Length: The minimum length of an external contour for exposure. Areas that have a
shorter external contour than the defined value are not exposed.

Point Filter: If enabled, successive vectors within a tolerance width are fused together and
the total number of vectors within a layer is reduced.

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• Point Filter Tolerance: The width within which successive vectors are fused together. A
higher number of short vectors are replaced by a lower number of longer vectors.

6.1.2.2.3. Offset
These are parameters for offset geometries that are the result of the inwards translation of part
edges. The translation causes gaps at inside corners within the offset geometries.

Offset Strategy: Select the strategy with which the gaps within the offset geometries are closed
at inside corners.

• OFFSET_ROUND: The offset geometry is rounded at the inside corners.

• OFFSET_MITER: The offset geometry is exposed as a point at the inside corners up to a

defined distance (Miter Limit). If the value is exceeded, the OFFSET_SQUARE strategy is
automatically applied.

• OFFSET_SQUARE: The offset geometry is cut off straight at inside corners so that the corner
sticks out.

Miter Limit: The factors that are multiplied by the value under Beam Compensation. The result
defines the maximum distance between the outermost border and the actual edge of the part
up to which the OFFSET_MITER strategy defined under Offset Strategy can be applied. If the dis-
tance is greater, the OFFSET_SQUARE strategy is automatically applied at the edge in question.

Arc Precision: The deviation of the outermost border from the intended offset geometry at a
rounded corner if the OFFSET_ROUND strategy definable under Offset Strategy is applied. Because
a rounded corner cannot be reproduced exactly using straight lines, there must be a deviation,
which can be defined.

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6.1.2.3. Volume Parameters

Areas with the volume type are surrounded by exposed areas from above and below.

Areas with the volume type can be exposed with hatch, fill contour, or border vector types.

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Vector Type Description

Hatch (volume) Hatches fill the inner area of the respective area of the volume type.
Fill contour A fill contour is a hole-filling contour between a border (volume) and the
(volume) hatches (volume).
Border (volume) A border is a contour on the outer area of the part that surrounds the
hatches (volume).

6.1.2.3.1. General

Hatch: If enabled, hatch scan vectors are exposed. Hatches can be arranged in different
patterns.

Pattern: Choose the pattern for hatch scan vectors from the following:

• STRIPES: Vectors are arranged in a stripes pattern. Use the Stripes tab to specify Stripe
Length and other stripe-related parameters.

• CHESS: Vectors are arranged in a chess pattern. Use the Chess tab to specify detailed
parameters related to the chess fields.

• PARALLEL: Vectors are arranged in a parallel pattern from end-to-end within the volume.
Use the Parallel tab to specify detailed parameters.

6.1.2.3.2. Stripes

Alternating: If enabled, the vectors alternate in their exposure direction.

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

• Merge Length: The length from which the hatches are grouped together. Hatch vectors that
are shorter than the defined value are merger with another hatch vector.

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

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Stripe Offset: The distance between the end of a vector and the start of the connecting vector.

Stripe Length: The length of the vectors within the strip pattern.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

6.1.2.3.3. Chess
These are settings for the hatch vector type that is arranged in a chess pattern.

Proximity Filter Factor: The factors that are multiplied by the value under Hatch Distance. This
value defines the distance between two hatch vectors within merged fields up to which the
shorter hatch vector is removed. This can prevent double exposure of vectors. With a Hatch Dis-
tance of, for example, 0.1 mm and a Proximity Filter Factor of 2, all hatch vectors that are within
0.2 mm or less of a longer hatch vector are removed.

Alternating: If enabled, the vectors alternate in their exposure direction.

Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

• Minimal Field Size: The minimum size of a field within the hatch pattern. Fields with a
smaller size than that defined are merged with a neighboring field.

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

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Field Offset: The distance between the individual fields of the hatch pattern.

Number Of Vectors: The number of hatch vectors within an individual field of the hatch pattern.

Hatch Distance: The distance between the hatches.

Field Order Strategy: The sequence in which the individual fields of the hatch sample are exposed.
The hatch pattern is fictitiously split into black and white fields, strongly resembling a chess
board. Options include:

• ORDER LINE BASED: With this method, the fictitious chess board is exposed row by row
from right to left. In doing this, all black fields in the first row are exposed first and then
all white. Only when one line of fields have been fully exposed will the neighboring line
of fields be exposed. This process is repeated for all lines of fields.

• ORDER FIELD BASED: With this method, the fictitious chess board is exposed by color from
right to left. In doing this, all black fields in the first row are exposed first and then the
second, and then all remaining rows. Only when all black fields have been fully exposed
will the white fields be exposed. The procedure for the white fields then corresponds to
that for the black fields, namely, the first line is initially exposed from right to left before
the second and all remaining lines of fields are exposed.

• ORDER SPIRAL IN: With this method, the fictitious chess board is exposed in a spiral form-
ation from outside inwards. In doing so, all black fields are first exposed in a spiral formation
from outside inwards. Only when all black fields have been exposed will the white fields
be exposed in a spiral formation from outside inwards.

• ORDER SPIRAL OUT: With this method, the fictitious chess board is exposed in a spiral
formation from inside outwards. In doing so, all black fields are first exposed in a spiral
formation from inside outwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from inside outwards.

Hatch Offset: The distance between the innermost border and the outermost hatch.

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6.1.2.3.4. Parallel
These are settings for the hatch vector type that is arranged in a parallel pattern.

Alternating: If enabled, the vectors alternate in their exposure direction.

Reduce Jumps: If enabled, the vectors within the parallel pattern are reapportioned in the
exposure sequence. This can avoid frequent positioning and setting down of the laser.

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Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

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6.1.2.3.5. Rotation

Align With Gas Flow: If enabled, the hatches are exposed against the direction of the gas
flow. For example, if the gas flows from the right side, the hatches are exposed in the hatch
pattern from left to right.

Start Angle: The start angle between the direction of the gas flow and the alignment of the
hatch.

Limitation Window: The rotation of the hatch matter from layer to layer takes place in a limitable
window. If the Align With Gas Flow function is enabled and the hatches are accordingly exposed
against the gas flow, a window of 180° is available for the rotation of the hatch pattern. This
means that the rotation can only take place in a window of 180°. The remaining 180° is ignored
in the rotation so that an unwanted alignment of the hatch with the direction of the gas flow
can be avoided. When the Align With Gas Flow is disabled, a window of 360° is available.

Angle Increment: The size of the angle around which the hatch pattern is rotated after each
layer.

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Gas Flow Direction Angle: The direction of the gas flow.

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6.1.2.3.6. Border

Sort Fill Contours Inwards: If enabled, the fill contours are generated from the outside in.

Number of Fill Contours: The number of fill contours to be generated.

Sort Borders Inwards: If enabled, the border is generated from the outside in.

Fill Contour Offset: The distance between the outermost fill contour and the innermost border.

Fill Contour Distance: The distance between the fill contours.

Contour Fill: If enabled, the total exposure area is filled with the border.

Number of Borders: The number of borders to be generated.

Border Distance: The distance between the borders.

Beam Compensation: The inwards indent of the outermost border. This enables you to com-
pensate for the width of the laser melt pool.

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6.1.2.3.7. Blocked Paths

Blocked Paths: If enabled, you can define parameters for Blocked Paths. Blocked Paths are
areas that are wider than required due to the width of the laser beam. In contrast, a non-expose
causes a gap in the part.

• Angle Threshold: The angle of part areas from which Blocked Paths is generated. By doing
this, the laser leaves the original route on the outermost border and exposure continues
in the direction of the corner so that this is also correctly exposed.

• Correction Factor: The length so that the inserted Blocked Paths is reduced from the
outside inwards in a corner. The actual reduction comes from the value for the Beam
Compensation and the Correction Factor multiplied together. With a value of zero, there
is no reduction in the Blocked Paths so that the exposure is right up to the outermost
edge of the part. This can cause over-exposure. In contrast, with a value of one, the Blocked
Paths is reduced from the outside inwards by the Beam Compensation. With a value of
two, the Blocked Paths is reduced from the outside inwards by twice the Beam Compens-
ation.

• Parabola Precision: The exposure accuracy in the case of a curved Blocked Paths.

• Erase Blocked Path: If enabled, no vectors are set if the laser beam is wider than the
build part area to be exposed. This means that there is no connection between the areas
and there is a gap in the build part. This function is deactivated as standard.

Traversal Strategy: The exposure method for the Blocked Paths:

• CONNECT_UNIDIRECTIONAL: The Blocked Paths is exposed once.

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• CONNECT_BIDIRECTIONAL: The Blocked Paths is exposed twice.

• MERGE: The Blocked Paths is exposed once. The exposure parameters correspond to those
of the borders.

6.1.2.4. Up-skin Remelting Parameters

Areas in the up-skin type do not present any further exposed layer above.

There are two options for processing the up-skins:

• Up-skin recoating: the area of the up-skin type is exposed twice. The substrate plate is not
driven upwards, instead a new powder layer is applied.

• Up-skin remelting: the area of the up-skin type is exposed twice. The substrate plate is not
driven upwards and no new powder layer is applied.

Regardless of the processing, up-skins can be exposed with hatch or border vector types.

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Vector Type Description

Hatch Hatches fill the inner area of the respective area of the up-skins.
(up-skin)
Border A border is a contour on the outer area of the part that surrounds the hatches
(up-skin) (up-skin).

6.1.2.4.1. General

Up-skin Remelting:

Pattern:

• STRIPES: Settings for the hatch vector type that are arranged in the stripes pattern.

• PARALLEL: Settings to the hatch vector type that is arranged in the parallel pattern.

• CHESS: Settings to the hatch vector type that is arranged in the chess pattern.

Hatch: Settings for the Hatch vector type. Hatches can be arranged in different patterns.

Tolerance: The minimum size of an area that is recognized as an up-skin. Areas that are smaller
than the defined value are assigned to the volume.

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Minimum Width: A limit value for an area in which no vectors are generated. This can prevent
the exposure of narrow areas.

6.1.2.4.2. Stripes

Alternating: If enabled, the vectors alternate in their exposure direction.

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

Merge: If enabled, vectors with a defined length are grouped together.

• Merge Length: The length from which the hatches are grouped together. Hatch vectors
that are shorter than the defined value are merger with another hatch vector

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

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Stripe Offset: The distance between the end of a vector and the start of the connecting vector.

Stripe Length: The length of the vectors within the strip pattern.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

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6.1.2.4.3. Chess
Proximity Filter Factor:

Alternating: If enabled, the vectors alternate in their exposure direction.

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

• Minimal Field Size: The minimum size of a field within the hatch pattern. Fields with a
smaller size than that defined are merged with a neighboring field.

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

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Field Offset: The distance between the individual fields of the hatch pattern

Number Of Vectors: The number of hatch vectors within an individual field of the hatch pattern.

Hatch Distance: The distance between the hatches.

Field Order Strategy: The sequence in which the individual fields of the hatch sample must be
exposed. The hatch pattern is fictitiously split into black and white fields, strongly resembling a
chess board.

• ORDER_SPIRAL_OUT: With this method, the fictitious chess board is exposed in a spiral
formation from inside outwards. In doing so, all black fields are first exposed in a spiral
formation from insider outwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from inside outwards.

• ORDER_LINE_BASED: With this method, the fictitious chess board is exposed row by row
from right to left. In doing this, all black fields in the first row are exposed first and then
all white. Only when one line of fields have been fully exposed will the neighboring line
of fields be exposed. This process is repeated for all lines of fields.

• ORDER_FIELD_BASED: With this method, the fictitious chess board is exposed by color from
right to left. In doing this, all black fields in the first row are exposed first, and then the
second row, and then all remaining rows. Only when all black fields have been fully exposed
will the white fields be exposed. The procedure for the white fields then corresponds to
that for the black fields, namely, the first line is initially exposed from right to left before
the second and all remaining lines of fields are exposed.

• ORDER_SPIRAL_IN: With this method, the fictitious chess board is exposed in a spiral
formation from outside inwards. In doing so, all black fields are first exposed in a spiral
formation from outside inwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from outside inwards.

Hatch Offset: The distance between the innermost border and the outermost hatch.

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6.1.2.4.4. Parallel

Reduce Jumps: If enabled, the vectors within the parallel pattern are reapportioned in the
exposure sequence. This can avoid frequent positioning and setting down of the laser.

Alternating: If enabled, the vectors alternate in their exposure direction.

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Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

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6.1.2.4.5. Rotation

Align With Gas Flow: If enabled, the hatches are exposed against the direction of the gas
flow. For example, if the gas flows from the right side, the hatches are exposed in the hatch
pattern from left to right.

Start Angle: The start angle between the direction of the gas flow and the alignment of the
hatch.

Limitation Window: The rotation of the hatch matter from layer to layer takes place in a limitable
window. If the Align With Gas Flow function is enabled and the hatches are accordingly exposed
against the gas flow, a window of 180° is available for the rotation of the hatch pattern. This
means that the rotation can only take place in a window of 180°. The remaining 180° is ignored
in the rotation so that an unwanted alignment of the hatch with the direction of the gas flow
can be avoided. When the Align With Gas Flow is disabled, a window of 360° is available.

Angle Increment: The size of the angle around which the hatch pattern is rotated after each
layer.

Gas Flow Direction Angle: The direction of the gas flow.

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6.1.2.4.6. Border
Number Of Border: The number of borders to be generated.

Offset: The distance from the contour to the outer edge of the part.

6.1.2.5. Up-skin Recoating Parameters

Areas in the up-skin type do not present any further exposed layer above.

There are two options for processing the up-skins:

• Up-skin recoating: the area of the up-skin type is exposed twice. The substrate plate is not
driven upwards, instead a new powder layer is applied.

• Up-skin remelting: the area of the up-skin type is exposed twice. The substrate plate is not
driven upwards and no new powder layer is applied.

Regardless of the processing, up-skins can be exposed with hatch or border vector types.

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Vector Type Description

Hatch Hatches fill the inner area of the respective area of the up-skins.
(up-skin)
Border A border is a contour on the outer area of the part that surrounds the hatches
(up-skin) (up-skin).

6.1.2.5.1. General

Up-skin Recoating:

Pattern:

• STRIPES: Settings for the hatch vector type that are arranged in the stripes pattern.

• PARALLEL: Settings to the hatch vector type that is arranged in the parallel pattern.

• CHESS: Settings to the hatch vector type that is arranged in the chess pattern.

Hatch: Settings for the Hatch vector type. Hatches can be arranged in different patterns.

Tolerance: The minimum size of an area that is recognized as an up-skin. Areas that are smaller
than the defined value are assigned to the volume.

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Minimum Width: A limit value for an area in which no vectors are generated. This can prevent
the exposure of narrow areas.

6.1.2.5.2. Stripes

Alternating: If enabled, the vectors alternate in their exposure direction.

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

Merge Length: The length from which the hatches are grouped together. Hatch vectors that are
shorter than the defined value are merger with another hatch vector

• Filter Length: The minimum length of the hatches. Hatches that are smaller than the
defined value are not exposed.

Stripe Offset: The distance between the end of a vector and the start of the connecting vector.

Stripe Length: The length of the vectors within the strip pattern.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

6.1.2.5.3. Chess
Proximity Filter Factor:

Alternating: If enabled, the vectors alternate in their exposure direction.

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

• Minimal Field Size: The minimum size of a field within the hatch pattern. Fields with a
smaller size than that defined are merged with a neighboring field.

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

Field Offset: The distance between the individual fields of the hatch pattern

Number Of Vectors: The number of hatch vectors within an individual field of the hatch pattern.

Hatch Distance: The distance between the hatches.

Field Order Strategy: The sequence in which the individual fields of the hatch sample must be
exposed. The hatch pattern is fictitiously split into black and white fields, strongly resembling a
chess board.

• ORDER_SPIRAL_OUT: With this method, the fictitious chess board is exposed in a spiral
formation from inside outwards. In doing so, all black fields are first exposed in a spiral
formation from insider outwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from inside outwards.

• ORDER_LINE_BASED: With this method, the fictitious chess board is exposed row by row
from right to left. In doing this, all black fields in the first row are exposed first and then
all white. Only when one line of fields have been fully exposed will the neighboring line
of fields be exposed. This process is repeated for all lines of fields.

• ORDER_FIELD_BASED: With this method, the fictitious chess board is exposed by color from
right to left. In doing this, all black fields in the first row are exposed first, and then the

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second row, and then all remaining rows. Only when all black fields have been fully exposed
will the white fields be exposed. The procedure for the white fields then corresponds to
that for the black fields, namely, the first line is initially exposed from right to left before
the second and all remaining lines of fields are exposed.

• ORDER_SPIRAL_IN: With this method, the fictitious chess board is exposed in a spiral
formation from outside inwards. In doing so, all black fields are first exposed in a spiral
formation from outside inwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from outside inwards.

Hatch Offset: The distance between the innermost border and the outermost hatch.

6.1.2.5.4. Parallel

Reduce Jumps: If enabled, the vectors within the parallel pattern are reapportioned in the
exposure sequence. This can avoid frequent positioning and setting down of the laser.

Alternating: If enabled, the vectors alternate in their exposure direction.

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Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

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6.1.2.5.5. Rotation

Align With Gas Flow: If enabled, the hatches are exposed against the direction of the gas
flow. For example, if the gas flows from the right side, the hatches are exposed in the hatch
pattern from left to right.

Limitation Window: The rotation of the hatch matter from layer to layer takes place in a limitable
window. If the Align With Gas Flow function is enabled and the hatches are accordingly exposed
against the gas flow, a window of 180° is available for the rotation of the hatch pattern. This
means that the rotation can only take place in a window of 180°. The remaining 180° is ignored
in the rotation so that an unwanted alignment of the hatch with the direction of the gas flow
can be avoided. When the Align With Gas Flow is disabled, a window of 360° is available.

Start Angle: The start angle between the direction of the gas flow and the alignment of the
hatch.

Angle Increment: The size of the angle around which the hatch pattern is rotated after each
layer.

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Gas Flow Direction Angle: The direction of the gas flow.

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6.1.2.5.6. Border
Number Of Borders: The number of borders to be generated.

Offset: The distance from the contour to the outer edge of the part.

6.1.2.6. Down-skin Parameters

Areas in the down-skin type do not have any further exposed layer below.

Down-skins can be exposed with hatch, fill contour, or border vector types.

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Vector Type Description

Hatch (down-skin) Hatches fill the inner area of the respective area of the down-skins.
Fill contour A fill contour is a hole-filling contour between a border (down-skin) and
(down-skin) the hatches (down-skin).
Border (down-skin) A border is a contour on the outer area of the part that surrounds the
hatches (down-skin).

6.1.2.6.1. General

Down-skin:

Hatch: Settings for the Hatch vector type. Hatches can be arranged in different patterns.

Pattern:

• STRIPES: Settings for the hatch vector type that are arranged in the stripes pattern.

• PARALLEL: Settings to the hatch vector type that is arranged in the parallel pattern.

• CHESS: Settings to the hatch vector type that is arranged in the chess pattern.

Layer Reference: How many layers below the current layer should be used for the calculation
of the Down-skins for the current layer. With a value of three, for example, the horizontal area
of the current layer is compared with the horizontal area of the layer that is three layers below
(nearer to the baseplate). The difference in the two horizontal areas is defined as the Down-skin
for the current layer - thus all new added areas that have not been exposed below the current
layer. The area that has already been exposed in the third layer and is not included in the difference
is defined as the volume for the current layer.

Maximal Surface Angle: The angle of a layer of metal powder to the overlying layer of metal
powder, from which this overlying layer of metal powder is recognized as the Down-skin.

Overlap: The width of the overlap area between a Down-skin and a volume. There is double ex-
posure in the overlap area (Down-skin + volume).

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6.1.2.6.2. Stripes

Alternating: If enabled, the vectors alternate in their exposure direction.

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

• Merge Length: The length from which the hatches are grouped together. Hatch vectors
that are shorter than the defined value are merger with another hatch vector

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

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Stripe Offset: The distance between the end of a vector and the start of the connecting vector.

Stripe Length: The length of the vectors within the strip pattern.

Hatch Distance: The distance between the hatches.

Hatch Offset: The distance between the innermost border and the outermost hatch.

6.1.2.6.3. Chess

Alternating: If enabled, the vectors alternate in their exposure direction.

Proximity Filter Factor:

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Shift Factor: A factor defining how frequently the total hatch pattern is translated in the Y-direc-
tion. A translation does not take place after every layer. A value of three means, for example, that
the hatch pattern returns to the original position after three layers. The hatch pattern was
therefore translated two times. After two translations, the hatch pattern is congruent with the
original hatch pattern. After the fourth layer, it is then translated for a second time.

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Merge: If enabled, vectors with a defined length are grouped together.

• Minimal Field Size: The minimum size of a field within the hatch pattern. Fields with a
smaller size than that defined are merged with a neighboring field.

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

Field Offset: The distance between the individual fields of the hatch pattern

Number Of Vectors: The number of hatch vectors within an individual field of the hatch pattern.

Hatch Distance: The distance between the hatches.

Field Order Strategy: The sequence in which the individual fields of the hatch sample must be
exposed. The hatch pattern is fictitiously split into black and white fields, strongly resembling a
chess board.

• ORDER_SPIRAL_OUT: With this method, the fictitious chess board is exposed in a spiral
formation from inside outwards. In doing so, all black fields are first exposed in a spiral
formation from insider outwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from inside outwards.

• ORDER_LINE_BASED: With this method, the fictitious chess board is exposed row by row
from right to left. In doing this, all black fields in the first row are exposed first and then
all white. Only when one line of fields have been fully exposed will the neighboring line
of fields be exposed. This process is repeated for all lines of fields.

• ORDER_FIELD_BASED: With this method, the fictitious chess board is exposed by color from
right to left. In doing this, all black fields in the first row are exposed first, and then the

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second row, and then all remaining rows. Only when all black fields have been fully exposed
will the white fields be exposed. The procedure for the white fields then corresponds to
that for the black fields, namely, the first line is initially exposed from right to left before
the second and all remaining lines of fields are exposed.

• ORDER_SPIRAL_IN: With this method, the fictitious chess board is exposed in a spiral
formation from outside inwards. In doing so, all black fields are first exposed in a spiral
formation from outside inwards. Only when all black fields have been exposed will the
white fields be exposed in a spiral formation from outside inwards.

Hatch Offset: The distance between the innermost border and the outermost hatch.

6.1.2.6.4. Parallel

Alternating: If enabled, the vectors alternate in their exposure direction.

Reduce Jumps: If enabled, the vectors within the parallel pattern are reapportioned in the
exposure sequence. This can avoid frequent positioning and setting down of the laser.

Filter Length: The minimum length of the hatches. Hatches that are smaller than the defined
value are not exposed.

Hatch Distance: The distance between the hatches.

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Hatch Offset: The distance between the innermost border and the outermost hatch.

6.1.2.6.5. Rotation

Align With Gas Flow: If enabled, the hatches are exposed against the direction of the gas
flow. For example, if the gas flows from the right side, the hatches are exposed in the hatch
pattern from left to right.

Limitation Window: The rotation of the hatch matter from layer to layer takes place in a limitable
window. If the Align With Gas Flow function is enabled and the hatches are accordingly exposed
against the gas flow, a window of 180° is available for the rotation of the hatch pattern. This
means that the rotation can only take place in a window of 180°. The remaining 180° is ignored
in the rotation so that an unwanted alignment of the hatch with the direction of the gas flow
can be avoided. When the Align With Gas Flow is disabled, a window of 360° is available.

Start Angle: The start angle between the direction of the gas flow and the alignment of the
hatch.

Angle Increment: The size of the angle around which the hatch pattern is rotated after each
layer.

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Gas Flow Direction Angle: The direction of the gas flow.

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6.1.2.7. Support Parameters

You can define specific build parameters for supports, including filter parameters to reduce the
total number of vectors.

6.1.2.7.1. Support
Slice Thickness: The thickness of the individual layers of metal powder.

Angle Tolerance: The tolerance up to which support vectors are assigned to the 1st group during
Sort Strategy Direction Clustering. With a value of 3, all support vectors with an alignment of ±3°
to the main alignment are considered to be support vectors in the main alignment.

Orthogonal Direction Weight: The tolerance up to which support vectors are assigned to the
2nd group during Sort Strategy Direction Clustering. With a value of 3, all support vectors with
an alignment of ±3° to the orthogonal alignment are considered to be support vectors in the
2nd group.

Remove Overlapping Contours: If enabled, double or overlapping support vectors are removed
if the values defined under Overlap Angle Tolerance and Overlap Tolerance are exceeded at the
same time.

• Overlap Angle Tolerance: The angle between two support vectors from which the criterion
for the removal of one of the two support vectors is considered to be fulfilled. Support
vectors with a larger angle to each other than defined are used for the removal. If the
value under Overlap Tolerance is also exceeded, one of the two support vectors is removed.

• Overlap Tolerance: The distance between two support vectors from which the criterion for
the removal of one of the two support vectors is considered to be fulfilled. Support vectors
with a greater distance to each other than defined are used for the removal. If the value
under Overlap Angle Tolerance is also exceeded, one of the two support vectors is removed.

Sort Strategy: The exposure methods for support vectors, i.e. the processing sequence of the
vectors.

• DIRECTION_CLUSTERING: With this method, a main alignment is determined for the support
vectors. This calculation is necessary because the structure of block supports and adaptive
cell supports means that they have two alignments that run orthogonally to each other.
The two directions are determined using the values under Angle Tolerance and Orthogonal
Direction Weight. The support vectors are split into three groups as the result of the
defined values and these groups are exposed successively:

1. All support vectors in the determined main alignment. Exposure of support vectors
from right to left

2. All support vectors orthogonal to the determined main alignment. Exposure of

support vectors from top to bottom

3. All other support vectors, for example, support vectors in the contour. Exposure
of support vectors according to the Nearest Neighbour method.

• NEAREST_NEIGHBOR: With this method, support vectors are exposed in such a way that
the nearest support vector to the support vector currently to be exposed is always the

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next to be exposed. The values defined under Angle Tolerance and Orthogonal Direction
Weight have no influence on the exposure

• NEAREST_NEIGHBOR_DIRECTION_WEIGHT:

6.1.2.7.2. Filter

Point Filter: If enabled, successive vectors within a definable layer are fused and the total
vector number is reduced.

• Point Filter Tolerance: The width of layers within which successive vectors are fused together.
In doing so, a high number of short vectors is replaced by a lower number of longer vectors.

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 Generating a Build File for SLM Machines

6.1.2.8. Scanning Parameters

Scanning parameters allow you to define exposure method, the sequence of the scan vectors,
power, speed, and other items associated with the laser processing.

Scanning Mode:

• Part: With this method, parts are exposed according to the sequence, irrespective of the
vector types, and finished for each layer of metal powder. As soon as the first part is finished
for the layer, the second part is exposed in the same layer.

• Platform: With this method, vectors are exposed according to vector type, for example, first
all hatches for all parts and then all borders for all parts.

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Generate a Build File

Scan Order

Every build strategy has a built-in order in which scan vectors are exposed. The order is shown in
the list under Scan Order. You can change the order using drag-and-drop or by using the Up and
Down buttons.

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 Generating a Build File for SLM Machines

Note:

When using a build file for simulation in Additive Print, there is a prescribed scan order
regardless of the settings in Additive Prep. The scan sequence is always simulated from
the inside out, that is, from hatch to contour scans.

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Generate a Build File

Laser Power: The laser power setting, in Watts.

Laser Speed: The 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, in mm/s.

Focus: The optical focus, in millimeters. A focus of zero designates a sharp point on the powder
bed. A positive focus value shifts the focal point into the powder bed, a negative value shifts the
focal point above the powder bed. Changing the focus affects the laser beam diameter at the surface
of the powder, which, in turn, affects the melt pool size.

6.2. Generating a Build File for EOS Machines

You must have an EOSPRINT 2 license, in the form of a dongle or from a license server, from EOS in order to
build an EOS build file. Additive Prep uses version 2.8 of the EOS API.

To generate an EOS build file:

1. Select the Build Processor option in the ribbon. The Build Processor panel appears in the right
side of the UI, as shown in the following figure.

2. In the Connect field, enter the host name or network address of your 3D printer and click Add.
Be sure the machine you want to connect to is up and running. It may take a minute or two
to make the connection. You will get a message such as "Configuration up to date. Connection
established." when the connection is made. If a connection cannot be established or gets inter-
rupted, you'll see: "No connection possible and no machine configuration found..." or a similar
message.

3. Check the Upload box to enable uploading of the build file to the specified machine.

4. Select a material from the list. It must be a material that your EOS license supports.

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 Generating a Build File for EOS Machines

5. Select a scan strategy for the part and then the support from the available options.

6. Enter a task name for the build file. When you have finished making changes, click the Assign
button to assign the changes to the selected workspace assembly, or click the Assign All button
to apply the changes to all the workspaces in the Build Volume.

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Generate a Build File

7. Click the green check box to generate the build file. Your build file will be uploaded to the
EOS machine upon completion. (You will need to Export (p. 171) to obtain the build file and
other files on your local computer. An exported build file format for EOS is .openjz with possibly
additional .task and/or .data files.) If your part is particularly large and complex, it may take a
minute or two for the build file to be generated. You will see the message "Open Slice Viewer
tool to view build file" when the operation is complete.

8. To make changes, simply adjust the parameters, click Assign or Assign All, and click the green
check box again and a new build file is generated.

9. Next you will probably want to review the build file in the Slice Viewer (p. 163) tool.

6.3. Generating a Build File for Renishaw Machines

You must have a ‘QuantAM Post Processor’ license from Renishaw in order to build a Renishaw build file.
Contact your Renishaw Account Manager at your local Renishaw office or the Renishaw website. Additive
Prep uses Renishaw QuantAM API version 1.4.1.1.

To generate a Renishaw build file:

1. Select the Build Processor option in the ribbon. The Build Processor panel appears in the right
side of the UI, as shown in the following figure.

2. Select a material from the list. The available options differ depending on which Renishaw machine
you selected under Build Volume Settings (p. 13).

3. Click the green check box to generate the build file. It is still an internal file at this point.
(You will need to Export (p. 171) to obtain a file on your computer. An exported build file format
for Renishaw is .mtt.) If your part is particularly large and complex, it may take a few minutes
for the build file to be generated. You will see the message "Open Slice Viewer tool to view
build file" when the operation is complete.

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 Generating a Build File for Renishaw Machines

4. To make changes, simply adjust the selected material and click the green check box again
and a new build file is generated.

5. Next you will probably want to review the build file in the Slice Viewer (p. 163) tool.

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Chapter 7: View the Build File with the Slice Viewer

After generating the build file, you can use the Slice Viewer tool to examine the individual slices of your
part, or the sequence of slices within the build. Click Slice Viewer in the ribbon to bring up the tool.
It may take several minutes to load all the layers from the build file. Depending on your machine and
model size, it could take up to an hour.

2D View
The Slice Viewer provides a two-dimensional view of any given individual slice in your part. In the 2D
View window, move the Slice slider to view a particular slice in the 2D View window. This slider can be
adjusted from 1 to the total number of slices in your part. Move the Vector slider to view the progression
of the laser scan vectors in the direction in which they are created within that particular slice. This slider
can be adjusted from 0 to the total number of vectors in the slice.

Viewing Slices
In the Viewing Slices area of the window, the green horizontal plane represents the current slice being
displayed in the Slice Viewer. Notice how the green slice plane moves up and down as you slide the
Slice slider up and down. Use your mouse, as needed, to orient the part in the Viewing Slices area for
best viewing of the green plane. Note that moving the part in this way does not affect the 2D slice
view.

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View the Build File with the Slice Viewer

Viewing Options
There are a number of options and features shown in the panel to the right of the 2D View. Not all
build files have the same options in the panel, depending on the machine type. For example, EOS build
files have fewer items shown because the information is not written by the API when creating the build
file. The remainder of the discussion about the Slice Viewer describes options specifically for SLM ma-
chines.

Here you can control what is shown in the Slice Viewer and get scan pattern summary information.

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There are several viewing options to control how the slices are displayed. Use the check boxes to toggle
on or off the following items:

• Contour - The border vectors (red arrows)

• Hatch - The bulk, or fill, vectors

• Arrows - The vector arrows

• Support - The support vectors (orange arrows)

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View the Build File with the Slice Viewer

Appearance
The background color in the 2D View window can be adjusted from white to black for more contrast
using the slider.

Animate Build Job

There are two slice animation options:

1. Animate Slices – Animates the build process slice-by-slice. The Slice slider begins from its current
position until it reaches the number of slices in the part, moving in the positive Z direction. The
animation can be paused, sped up, and slowed down using the appropriate buttons.

2. Animate Vectors – Animates the current slice’s scan vectors. The Vector slider begins from zero until
it reaches the total number of vectors in the slice, moving in the positive X direction. The animation
can be paused, sped up, and slowed down using the appropriate buttons.

Build Parameters
Here you can see the most important build parameters, namely power and speed, for each type of scan
vector in the build file. For example, in the Slice Viewer dialog above, the hatch - volume scans will be
exposed with a laser power of 370 Watts and a scan speed of 1335 mm/sec. Remember that power and
speed settings are built into the build strategy that you choose but may be changed in the Build Pro-
cessor, under Scanning Parameters (p. 155).

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Chapter 8: Estimate Costs of the Build Job

After generating the build file, you can use the Cost Estimator tool to obtain an estimate of the total
cost to build the job based on the cost, material, and build time parameters defined for your selected
machine.

Note:

Cost information is built into the machine profiles for SLM machines only. Therefore if you
choose a machine profile other than SLM, you'll see a zero under machine costs in the estim-
ate.

To obtain a cost estimate to build what is currently in the Build Volume on your chosen machine (after
you have generated a build file (p. 99)):

1. Select the Cost Estimator option in the ribbon. The Cost Estimator panel appears in the right
side of the UI.

2. Review the information in the panel, as needed. Click the calculate button to generate
the cost estimate, which then appears in the panel.

3. Click the export button to export the estimate to a .csv file.

If you make changes to build parameters and regenerate a build file, the cost estimate information will

be incorrect for the new build file. Click the calculate button again to update the cost estimate.

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Estimate Costs of the Build Job

To determine the cost estimate, the Cost Estimator uses the following information from your project:

• Machine (Selected under SpaceClaim Options > Additive Prep Machines (p. 183) or Settings >
Manage Machines. Here you will see the Length and Width of the baseplate, used in the calculation
of Total Material.)

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• Material (Selected under SpaceClaim Options > Additive Prep Materials (p. 189). Here you will see
the Powder Density, Material Loss (percentage), and Cost settings for your chosen material.)

• Build Strategy (Selected on the Build Processor panel)

• Build File (Represents the scan pattern for the part(s) and supports and is generated from the
Build Processor (p. 99))

• Profit (Defined under SpaceClaim Options > Additive Prep Options (p. 180))

• Currency Symbol for Export (Defined under SpaceClaim Options > Additive Prep Options (p. 180))

The largest contributing factor to the Estimated Total Price is the Machine Cost, which is directly related
to the build time. The build time calculation in the Additive Prep application is done with the same al-
gorithm as in the SLM machines. It sums up the laser path times plus the jump times between the laser
paths. This represents the exposure time. The recoater time per layer is normally defined in the SLM
machine settings. Exposure and recoater time result in the build time for the buildjob.

The Total Material in the cost estimate is the amount of powder necessary for the build, which is calcu-
lated as volume x powder density. The volume is length x width of the baseplate x the height of the
part in its build orientation plus the Z-Offset.

Material loss is a percentage of the total material and is due to unrecoverable metal powder loss from
gas flow during the build or in post-processing.

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Chapter 9: Export for Simulation or Print

Two export functions are available. Use the Export CLI button as a quick shortcut for exporting CLI files,
such as required for EOS machines. Use the Export button to export the full set of files associated with
the Build Volume. We'll discuss the full set of files first.

9.1. Export the Full Set of Files

Click Export from the Additive Prep ribbon to export the project files to a folder called Build Volume
(with time-stamp) to a file location of your choice. Exported files include:

• ansys_additive_print.zip — build file for Additive Print, if you generated a build file

• baseplate.stl — only the baseplate geometry

• build_job.scdoc — a SpaceClaim file containing everything in the Build Volume assembly

• part.stl — all the part geometries in the Build Volume that are not suppressed, without their
supports

• support_vless.stl — all the volumeless supports, if any, that are not suppressed for all the parts

• support_solid.stl — all the solid supports, if any, that are not suppressed for all the parts

• print_file.slm — machine instruction file required to print the part(s) on SLM machines, if you
generated a build file

Or partname.cli and partname_s.cli — machine instruction files required to print the part and
volumeless support on EOS machines (p. 177), if you generated a build file

Or the appropriate machine instruction files generated by the Build Processor from EOS or Ren-
ishaw, depending on your selected machine, if you generated a build file

The following figure shows example files from an Export with a build file generated for an SLM machine.

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Export for Simulation or Print

9.1.1. Recommended Workflow with Additive Print

Use the following workflow when you will be simulating the additive process in Additive Print.

1. Open or create your part in SpaceClaim.

2. Use Additive Prep to orient your part and generate supports.

3. Suppress parts not intended for simulation.

Currently, the Additive Print application has a limitation in that it allows only one build part for
an AM simulation. (There can be multiple bodies, but they have to be on the same part.) If you
have multiple workspaces in the Build Volume, right-click and select Suppress for Physics on the
workspaces you will not be importing into Additive Print for simulation.

4. If you plan to use a build file in Additive Print, generate the build file.

The build file will be written for whichever workspaces are not suppressed.

5. Export from Additive Prep. (Click the Export option from the Additive Prep ribbon.)

You will need the build file, or the part and support .stl files, later, so be sure to do an Export from
Additive Prep rather than a Save As... from SpaceClaim.

6. Open Additive Print.

7. Import the build file, or the part and then the supports, as usual.

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 Export the Full Set of Files

8. Proceed with the simulation as usual.

9.1.2. Recommended Workflow with Workbench Additive

Use the following workflow when you will be simulating the additive process in Workbench Additive.

1. Open or create your part in SpaceClaim. Do this without going through Ansys Workbench.

2. Use Additive Prep to orient your part and generate supports.

Most people will choose to use a layered tetrahedral mesh method for their part once in Workbench
Additive but if you plan to use a Cartesian mesh, set intrusion parameters to zero when generating
supports.

3. Suppress parts not intended for simulation.

If you have multiple workspaces in the Build Volume, right-click and select Suppress for Physics
on the workspaces you will not be transferring to Workbench for simulation.

4. Join the supports together into one support entity. Do this for each part you want to transfer to
Workbench such that you have one support entity per part.

Select all the supports (select, shift select) associated with a part. Click the Facets tab in the ribbon
and then click Join (in the Organize group). Do the same for each part to be transferred to
Workbench for simulation.

By doing this step, you will avoid bringing all the supports into the Mechanical application as in-
dividual stl supports.

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Export for Simulation or Print

5. Transfer data to Ansys Workbench.

Select the Workspace. Click the Workbench tab and then the Workbench button under Ansys
Transfer in the ribbon. You will be prompted to save the SpaceClaim document if you haven't
already done so. When Workbench opens you will see the Mechanical Model system containing
the assembly geometries.

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 Export the Full Set of Files

6. Create the analysis system.

In Workbench, scroll down to Custom Systems and add (by double-clicking) either the AM Inherent
Strain or the AM Thermal-Structural system.

Drag the Geometry cell of the Mechanical Model onto the Geometry cell of the AM system. Your
systems should look like one of the systems shown in the following figure.

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Export for Simulation or Print

7. Double-click the Model cell in the AM system to bring up Ansys Mechanical. When Mechanical
opens, you will see one STL Support object per part under the AM Process object. Proceed with
the AM Process Simulation as usual.

Once you've transferred data to Workbench using Ansys Transfer, the systems are tied together such
that if you close out of the Workbench application, the SpaceClaim application instance associated
with that Build Volume will close as well.

Known Issues
• If you do not join the supports together into one entity for each part, they will be imported into
the Mechanical application as many individual stl supports and it may be unmanageable to continue
on for simulation. This is true regardless of whether you use the Ansys Transfer buttons (Workbench
or Mechanical) when opening Mechanical or launching Mechanical directly.

• 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 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.

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 Export CLI Files

– 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 (p. 1) are accessible in SpaceClaim by clicking File > SpaceClaim
Options > License and then checking/unchecking Additive Prep.

9.2. Export CLI Files

Click Export Cli from the Additive Prep ribbon to export a CLI file of the part/supports to a file location
of your choice. Common Layer Interface (CLI) is a universal, neutral file format for input of geometry
information for layered technologies such as additive manufacturing. Additive Prep uses the ASCII data
format.

CLI files from Additive Prep include:

• Outline of the part (partname.cli)

• Hatch vectors of volumeless supports (partname_s.cli)

CLI files from Additive Prep do not include:

• Hatch vectors of the part

• Contour vectors (border, etc.) of the part

• Hatch vectors of solid supports

• Contour vectors (border, etc.) of solid supports

Known Issues
Incompatibility with EOSPrint — CLI files exported from Additive Prep may include negative X-Y co-
ordinates for parts/supports. This is most likely to be the case when you are using an SLM machine,
since the Zero Point (p. 185) is located at the center of the baseplate (default for all SLM machines).
EOSPrint, the process management software for EOS systems, cannot process entities with negative
coordinates on the plate and so parts/supports may get cut off upon importing the CLI file into EOSPrint.
If you know you will be using an EOS machine, position the part (p. 8) and supports to have only
positive coordinates, or select an EOS machine (p. 13), which has the Zero Point at the corner.

SpaceClaim hangs when exporting CLI on Chinese localized system — Using Chinese localization,
whenever a part, with or without supports, is exported as a CLI file, the 3D object is added to the export
folder but SpaceClaim stops responding before the CLI file is created.

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Chapter 10: Customize Additive Prep Startup Options
You can customize common Additive Prep options using SpaceClaim's options window, accessible from
the File menu. Think of these as startup preferences.

To change Additive Prep options:

1. Select SpaceClaim Options from the File menu to display the SpaceClaim Options window.

2. Click Additive Prep from the navigation panel on the left for general options. Click Additive
Prep Machines for machine-specific options. Click Additive Prep Materials for material-specific
options.

3. Modify the options on the page.

4. Click Save Changes (on Machines and Materials options pages) and then OK to save all your
changes and close the window.

Additive Prep options are "sticky," in that once you have set them, they will remain that way each time
you open SpaceClaim, until you change them again.

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Customize Additive Prep Startup Options

10.1. General Options

Units
Regardless of whether your part is a design body (.scdoc) or a faceted body (.stl), dimensions of the
part must be in units of millimeters (mm) for Additive Prep’s internal calculations. While .stl files are
unitless, the SpaceClaim application has to assign a unit system to .stl files for certain functionality to
work. If you are creating new geometry in SpaceClaim it will use the units that are set under SpaceClaim
Options > Units. This should be set to millimeters if you will be working in Additive Prep. However,
there is also an option to override units when saving an .stl file from SpaceClaim. So if you are starting
with an existing .stl file, it is possible it may have been saved from SpaceClaim in units other than milli-
meters. If this is the case, you will need to re-save the .stl file from SpaceClaim in millimeters before
bringing it into Additive Prep.

Tessellation Resolution
Here you can set resolution options to control the size and shape of triangular facets in geometries
with curvature, used in the calculation of orientation maps and support regions. Remember, Additive

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 General Options

Prep will use the existing facets if your original part is a faceted body (.stl). Faceting by Additive Prep is
performed only for non-faceted parts. Options include:

• Low: lowest resolution—fewest facets created. (Defaults: Surface Deviation = 0.50 mm, Angle
Deviation = 25°)

• Medium: medium resolution—a medium amount of facets created. (Defaults: Surface Deviation
= 0.10 mm, Angle Deviation = 15°)

• High: highest resolution—greatest number of facets created. (Defaults: Surface Deviation = 0.01
mm, Angle Deviation = 5°)

The default values of Surface Deviation and Angle Deviation are uniquely defined for each of the low,
medium, and high resolution settings. (Notice that the defaults change when you switch from one se-
lection to another.) As soon as you adjust one of the individual settings of Surface Deviation or Angle
Deviation, you are customizing the controls for more precise control of the faceting. The control para-
meters are defined as follows:

Surface Deviation: This is the distance between a chord drawn through a curved cross-section of the
model and the curve’s most distal point, in millimeters. It is used as a more global specification. The
smaller the value, the lesser the deviation from the actual part surface and the greater the number of
resulting facets.

Angle Deviation: This is the angular distance that the chord line makes with a line tangent to the cross-
section curve, in degrees. It is used for controlling more localized faceting along curves with small radii
compared to the overall part size. The smaller the value, the greater the number of resulting facets.

An additional option may be used as described below:

Edge Length: This is the overall maximum value for facet edges, in millimeters. Note that smaller facet
edges may be created. The application attempts to meet your desired edge length setting, but in some
design scenarios, may create an edge length that is less than what you specify for Edge Length, to best
accommodate the design. This parameter is used to obtain more uniform triangle sizes with better aspect
ratios.

Miscellaneous
Preserve Original Model Document On Create: Check this box if you want Additive Prep to open a
new document (a tab at the bottom of the user interface) when you click Create to create the Build
Volume. This is a good option when you want to preserve the original part because the design has
been approved or certified, for example. The default (unchecked) uses the existing document when
you click Create, such that changes you make in Additive Prep affect the original document. This scenario
is necessary for scripting in Ansys Workbench.

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Customize Additive Prep Startup Options

Build Strategy User Profiles

Clicking the "Open User Profile Directory" link opens Additive Prep's AppData directory where your
custom build strategies are stored. We recommend you do not delete, add, or rename files directly in
the file manager accessed from within Additive Prep. If you do, you will need to close the SpaceClaim
application and restart in order for those changes to take effect. Rather, you should define new build
strategies in the Build Processor (p. 99).

Cost Estimation
Profit: A built-in profit surcharge based on a percentage of total costs.

Currency Symbol for Export: Symbol to be used in Cost Estimation export file. There is no currency
associated with the cost calculations, this field simply allows you to identify a symbol to be used in the
report.

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 Machine Options

10.2. Machine Options

The Additive Prep Machine Options form is shown below. This is the same form that you will find under
Settings > Manage Machines (p. 13). After making changes on the form, be sure to scroll to the bottom
to click Save Changes. Use the Discard Changes button to clear the form whenever needed.

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Customize Additive Prep Startup Options

Select Default Machine

Select a machine from the drop-down list to be the default machine upon application startup.

Select Machine
To add or edit machines into your customized machine user profile, start with one of your existing
custom machines, or from an Ansys-defined machine, as a starting point.

• Click New Machine from Selected to create a new machine from the machine currently selected
in the drop-down under Your Machines (Custom).

• Click Delete Machine to delete the machine currently selected in the drop-down under Your
Machines (Custom) from your machine user profile.

• Click New Machine from Template to create a new machine using one of the predefined tem-
plates available under the drop-down Ansys-defined Machines (Templates).

After any of the above actions, make your changes to the options on the form, as appropriate. Scroll
down to the bottom of the page and click Save Changes.

General Info
Whether it's Susi, Big Red, or Left Corner, give your machine a unique Name to easily distinguish it. Type
and Manufacturer are read-only information fields, read from your selected machine.

Material and Build Strategy

Select the default material to be used at application startup.

Note:

The machine material assigned here will override any material that may be assigned in
SpaceClaim properties (right-click an object, Properties > Material).

Select the default build strategy (p. 100) to be used at application startup.

Machine Setup
Platform Size

These settings control the size of the Build Volume as shown here.

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 Machine Options

• Length: Dimension of the baseplate in the X direction, in millimeters.

• Width: Dimension of the baseplate in the Y direction, in millimeters.

• Thickness: Thickness of the baseplate (Z direction), in millimeters. The thickness is included in

the Build Height.

• Build Height: Height of the Build Volume, in millimeters. This is typically the height that the
build chamber allows on your machine.

When you create a new machine from a template, the size parameters automatically populate for the
new machine.

Zero Point

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• Zero Point: Location of the origin on the top surface of the baseplate. Options include placing the
origin at the center or at the corner of the baseplate.

Lasers

Here you can identify multiple lasers.

Part-free Areas

Here you can identify areas on the baseplate designated as no-scan regions, such as locations of bolt
holes. If there are four corner bolt holes, add four separate part-free areas. Part-free areas are defined
as cylindrical bodies. Their centers should be located relative to the zero point of the Build Volume.

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 Machine Options

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You will be prevented from moving or orienting parts into a part-free area. Your part will appear red
indicating a collision with part-free areas. Collision detection is performed on design bodies (.scdoc)
only, not on faceted bodies (.stl), which includes supports.

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 Material Options

10.3. Material Options

Select Material
Here you select a material from the drop-down list. If you want to customize it, click New Material
from Selected and then customize the properties listed under Material.

Note:

At this release, only AlSi10Mg is available.

Material Properties
Solid Density: The density of the processed powder, in kg/m3.

Powder Density: The density of the unprocessed powder, in kg/m3.

Material Loss: The rate of powder that is lost during the build process (for example, through the sieving
process), in %.

Cost: The price of the powder per kg.

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Overhang Angle: Overhang Angle for this material. This is the angle measured from the horizontal
baseplate (0 degrees) to the surface of the part. Any surface or edge with an angle measuring less than
the Overhang Angle will be supported.

Filter Surface Region: Filter Surface Region for this material. This is the minimum area size, in mm2,
for the generation of supports. Surfaces that are smaller than the defined value will not be considered
regardless of their overhang angle and will not have supports generated for them.

Filter Line Region: Minimum line length, in mm, for the generation of supports. Lines that are smaller
than the defined value will not be considered regardless of their overhang angle and will not have
supports generated for them.

Material User Profiles

Clicking the "Open Material User Profile Directory" link opens Additive Prep's AppData directory where
your custom materials are stored. We recommend you do not delete, add, or rename files directly in
the file manager accessed from within Additive Prep. If you do, you will need to close the SpaceClaim
application and restart in order for those changes to take effect. Rather, you should delete, add, or rename
custom materials using the Delete Material, New Material from Default, and New Material from Selected
buttons at the top of the form.

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