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· Dr. Michael Blank

Simulation software for laser DED with wire or powder

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.

Book a callHow the method works
With a computational meshWith free particles (Synafloat)
A computational mesh on the left, free particles on the right. While four layers are deposited, only the mesh on the left has to be adapted to the growing part; the particles follow the material.

Both methods describe a moving free surface but represent the material differently in numerical terms. A computational mesh divides the domain into connected cells, whereas a mesh-free particle method (SPH) represents material state on moving particles.

Re-meshing a moving surface

A mesh-based method represents the domain with fixed connections between its cells. As the melt pool moves, the cells distort until the mesh has to be rebuilt. Only then can the solver continue the simulation.

Material state on particles

A particle-based method carries material state, such as temperature and momentum, on discrete particles that move with the material. The positions of the particles define the free surface.

Limits of this comparison

This comparison describes two numerical methods and is not a benchmark, because it compares neither runtime, accuracy nor cost of specific software products.

The fixed Eulerian grid

A fixed Eulerian grid with surface tracking (VOF, level set) does not rebuild its mesh. It has to cover the build volume in advance at melt-pool resolution, and the domain grows with every layer.

Re-meshing or particle method

Mesh-based re-meshingMesh-free particle method (Synafloat)
Representation of the domainA grid of connected cells covering the domain.Discrete particles carrying material state.
Response to a moving free surfaceThe grid cells distort and the mesh has to be rebuilt.There are no grid cells to distort.
Consequence of growing deformationRe-meshing frequency rises with surface change.The particles move with the material, so no re-meshing is needed.
Numerical method familyMoving mesh (Lagrangian, ALE, PFEM).Lagrangian, particle-based formulation (SPH).

Related pages

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.