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Stratasys & e-Xstream partnership
Sandra Cherubini, e-Xstream engineering
Digimat predictive simulation solutions
for FDM technology
3Copyright 2017 e-Xstream engineering
• A global team of 60 PhDs & Engineers 100% focused on
advanced material modeling
• World leader in multi-scale material modeling with more than
500+ customers
– 400 Commercial & 100 Academic customers
– 25 out of the top 30 plastic/composite
material suppliers
– 35 out of the top 50 Auto Suppliers
– 20 out of the top 25 biggest Auto OEMs
– The major Aero Airframes & Engine OEMs
– Some major Aero Suppliers
– Major E&E Companies
• An MSC Software company since Sep 2012
• Fast growing business – 3x over last 5 years
• Part of Hexagon Manufacturing Intelligence since April 2017
e-Xstream, The material modeling company
Copyright© e-Xstream engineering, 2017 41/20/2018
DIG
IMA
T
Virtual testing lab to screen and understand the effects of material, microstructure, defect on material performances
Material database to calibrate, store and exchange Digimat materialmodels
Mapping solutions
Connection to FEA to apply multiscale methodology and account for the microstructure, defect, process at component level
Virtual allowable computation
Process modeling for plastic additive manufacturing
Since 2017,
Digimat includes
the first release of
Digimat-AM
for the simulation of
polymer 3D printing
Digimat, Award winning platform for effective and efficient
engineering of materials & structures
5Copyright 2016 e-Xstream engineering
Digimat is used to speed-up material development,
reduce testing and improve product performance
Speed-up the development of new material systems
Reduce the cost and time of physical material testing
Optimize the weight and performance of plastics & composites structures
7Copyright 2017 e-Xstream engineering
Digimat bridges the gap between the manufacturing
& performance via the material microstructure
9Copyright 2017 e-Xstream engineering
Numerical tools are needed to support the AM market
move from rapid prototyping to direct manufacturing
Source: stratasys.com
According to Wohlers Report 2016, the additive manufacturing (AM) industry grew 25.9% (CAGR – Corporate Annual Growth Rate) to $5.165 billion in 2015. The CAGR
for the previous three years was 33.8%. Over the past 27 years, the CAGR for the
industry is an impressive 26.2%Source: Forbes.com
10Copyright 2017 e-Xstream engineering
e-Xstream Eco-System for
Effective & Efficient
Engineering of AM
Materials, Processes & Parts
Modeling Solution
End-User
Material Suppliers
R&D
Printer OEMs
11Copyright 2016 e-Xstream engineering
Digimat Additive Manufacturing Solution
Material Process Part PerformanceA
dditiv
e L
ayer
Manufa
ctu
ring
FDM/SLS
Material Engineering
Mechanical
Thermal
Electric
Process Simulation
Warpage
Residual Stress
Microstructure
Part Performance
Stiffness
Failure
Print Direction
Reinforcement
Dig
imat
Mate
rial
12Copyright 2017 e-Xstream engineering
Stratasys is partnering with e-Xstream to offer predictive
simulation solutions tools that enable the AM value
• Software Strategy
Develop Tools that Enable the Value of AM
Value Add
CAE Analyst
AM ProgrammerOps/Manufacturing
Designer
MANUFACTURING
DesignPrinter pre-processing
Optimized FDM workflow:
PrintingPost-
processingFinal part
• MinimizedWarpage
• Masteredperformance
Simulation
13Copyright 2016 e-Xstream engineering
Manufacturing Process Simulation
Material microstructure
Material characterization (mechanical, thermal, electrical)
Engineering of AM Parts & Systems
e-Xstream is partnering with Stratasys to support the
engineering of printed production parts
(same workflow as injection)
14Copyright 2017 e-Xstream engineering
Digimat 2018.0 delivers the first material models of
Stratasys ULTEM™ 9085 resin and a complete process
package for Fortus 900mc
AM Simulation
Material Models
- Process
- Structural
Printer Model
Toolpath Data
ULTEM 9085 Insight part data
Fortus 900mc
15Copyright 2016 e-Xstream engineering
High performance Advanced material models
Insight infill database
Increase the AM material
portfolio!
Materials – Digimat-MF, FE & MX support the complex
microstructure resulting from FDM printing…
Benefits
• Down select materials using virtual
engineering
• Materials engineered for the
application• Electrical conductive bead path
• High strength Composite
Reinforcement
• Low CTE Materials
16Copyright 2016 e-Xstream engineering
Process – Digimat-AM aims at predicting warpage and
residual stresses of FDM parts
Without anchor pins – upward warpage
With anchor pins – downward warpage
17Copyright 2016 e-Xstream engineering
Performance – Digimat-RP supports the engineering
of printed production parts
18Copyright 2016 e-Xstream engineering
Simulating effects of warpage in an additively
manufactured composite layup tool
• Advantages of composite tools
– reduced time-to-market
– increased geometry complexity
– lowering development and manufacturing costs
19Copyright 2016 e-Xstream engineering
Benefits
Reduce trial & errors
Gain time & money
Warpage compensation
Simulating effects of warpage in an additively
manufactured composite layup tool
Strategy
Comparison between measured warpage and
Digimat-AM warpage prediction (right)
Results
Additive manufacturing is a true
multi-scale challenge
Complex thermomechanical
loadings during the layer-by-layer
deposition of the material
Thermal history of the material
deposition
Challenges
FDM process simulation via a
multiscale approach as a function
of process setup and material
choice
Thermomechanical analysis
Predict the resulting warpage
20Copyright 2016 e-Xstream engineering
Full printing workflow connects real world with
simulation
Part designPrinter pre-processing
Virtual printing
Warpageprediction
Physical printing
Validateprinting process
Warpage correction decreases significantly the maximum deviation
between the reference geometry and the as-printed part
21Copyright 2016 e-Xstream engineering
Validate the FDM part design as a function of the
material and the printing process parameters
Multiscale non-linear
material model
Process data
transfered to
structural mesh
• Residual stresses
• Local printing
direction
• Local porosity
• Local filler
microstructure
As-manufactured
part performance
Strong coupling
Copyright© e-Xstream engineering, 2017 251/20/2018
Digimat Additive Manufacturing Solution value proposition:
modeling to support fast ideas to the market
• Understand and optimize machine parameters
• Promote your printers with relevant parameters and materials
OEM Printer
• Design & understand material behavior
• Promote your AM grades for both process & performances
Material Supplier
• Perform advanced research
• Provide expertise and guidelines R&D Centers
• Easy access to printers and materials
• Save time & cost by printing right the first time
• Build knowledge & guidelinesEnd Users