Causes of varying bead height
Even along a straight toolpath, heat and melt flow change. Bead height can therefore vary while the parameters stay fixed.

Simulation, demonstrator
Simulation software for laser DED with wire or powder
The articles go deeper into the method behind the software, from bead geometry to the choice of simulation approach.
Even along a straight toolpath, heat and melt flow change. Bead height can therefore vary while the parameters stay fixed.

Simulation, demonstrator
When the free surface of the melt pool deforms, the cells of a moving computational mesh have to be adapted. A particle method needs no cells.

Schematic, illustration
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You talk to Dr. Michael BlankThe founder has researched particle-based melt-pool simulation since 2017 and earned his doctorate in the field.
Partner: Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU). Synafloat is a spin-off of FAU.
Incubated at the ESA Business Incubation Centre in Bremen since November 2026.