Simulation software for laser DED with wire or powder
Parameters for your part, before the next print
In a pilot project we compute parameters for your part and deliver them as an adjusted machine file that your team checks before the print. We set the scope for each enquiry.
We prepare the offer individually for each enquiry.
Inputs and data
For the first call, non-confidential details are enough: part and parameter question, machine, material, wire or powder.
We check fit and data, including the G‑code dialect of your machine control.
Depending on the enquiry, you send for example
- the file from your CAM, with toolpath and current parameters
- machine, material, wire or powder, setup and required layer height
- if available: a measured bead, such as a cross-section
Matching with your measurement
We match the model with measurements from your machine, such as a cross-section. Without a measurement the pilot project becomes an exploratory study, which delivers simulated trends without a calibrated comparison.
| Path | When | Result |
|---|---|---|
| Calibrated | a measured bead with method, units and uncertainty is available. | Measured and simulated contour, their deviation and uncertainty, plus the simulated trends. |
| Exploratory | no documented measurement is available. | Simulated trends, material and data gaps, and the measurement a calibrated comparison would need. |
When we calibrate, we adjust the model to your measured bead.
Parameters for the whole toolpath
We simulate parameter strategies for the whole toolpath, each with a different temperature target at the same layer height. The software adapts laser power, travel speed and material feed along the toolpath.
An adjusted parameter set from the demonstrator, not the result of a pilot project.
Handover
Your team receives the adjusted machine file, checks it before the print and runs the print on your machine.
Depending on the enquiry, the handover includes
- Adjusted machine file (G‑code)
- A work result for your further process development, checked by your team.
- Report
- The comparison of the strategies with assumptions, model limits and uncertainty.
- Print plan and review meeting
- A plan for your print, then a meeting on the results.
Platform, screenshot
Today we already compute optimized process parameters for you in a pilot project, based on simulation studies that we calibrate with your measurements. In future your team will use the same software through its browser.
Platform: in development
Limits of the pilot project
The simulation computes possible parameters for your part but replaces neither the print nor the qualification.
Schematic, illustration
We simulate
Adjusted machine file (G‑code)
Handover
Your team
- checks
- the machine file, machine safety and operating limits before the print.
- runs
- the print on your machine and measures the result.
- is responsible for
- the qualification within its own quality system.
- Assessed separately
- New calibration, further applications, certification.
- Not promised
- The qualification of your part, a calibrated comparison without a measurement and savings as a result. Build time, energy or the number of prints are not a contractual result.
Three target groups
- Process development at a contract manufacturer
- When a new part goes into qualification, you need a parameter set for the next print.
- Application engineering at a machine builder
- When a customer brings their part to your machine, you need parameters for their toolpath.
- R&D and qualification
- You need traceable parameters and a rationale before the print runs.
Pilot project questions
Is this AI?
No. The software is a physics-based simulation that models the melt pool without a mesh, with freely moving particles (SPH). With measurements from your machine, we calibrate the simulation to your machine and your material.
Who owns my data and the machine file?
We claim no rights in your data and use it only to carry out your project. Once paid in full, you hold a right without time limit to use and adapt the results, including the machine file, for your own operations.
Further questions, for example on cost, inputs and measurement, are answered on the FAQ page.
Let’s talk about your part
In the first call we clarify whether the simulation answers your parameter question.
Book a callYou pick the slot on book.synafloat.com.
You talk to Dr. Michael BlankThe founder has researched particle-based melt-pool simulation since 2017 and earned his doctorate in the field.
