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Simulation software for laser DED with wire or powder

Articles on melt-pool simulation

The articles go deeper into the method behind the software, from bead geometry to the choice of simulation approach.

  1. · Dr. Michael Blank

    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

  2. · Dr. Michael Blank

    Melt-pool simulation with or without a mesh

    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

We are reviewing further articles.

Let’s talk about your part

In a call we clarify whether the simulation answers your parameter question.

Book a call

You pick the slot on book.synafloat.com.

Enquiry via the contact form

You talk to Dr. Michael BlankThe founder has researched particle-based melt-pool simulation since 2017 and earned his doctorate in the field.

For the first call

  • A short, non-confidential outline of your part and question
  • Machine, material, wire or powder

In the pilot project, per enquiry

  • Matching the simulation with your experiments
  • Parameter strategies for the whole toolpath
  • Adjusted machine file

Funding

EXIST – from science to business
Funded by the EXIST Business Start-up Grant at the FAPS institute of FAU, funding period 09/2025 to 08/2026.
FAU – Friedrich-Alexander-Universität Erlangen-NürnbergFAPS – Institute for Factory Automation and Production Systems, FAU

Partner: Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU). Synafloat is a spin-off of FAU.

ESA BIC Northern Germany

Incubated at the ESA Business Incubation Centre in Bremen since November 2026.