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Hexagon and Sciaky unlock potential of EBAM for high-value parts

Simufact DED process simulation optimizes fastest metal 3D printing process in G-code before deposition

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Hexagon’s Manufacturing Intelligence division has entered a partnership with Sciaky, Inc, a leading supplier of industrial metal 3D printing solutions and a subsidiary of Phillips Service Industries, Inc. (PSI), to enhance its innovative EBAM technology with Simufact predictive analysis and simulation tools

Sciaky’s turnkey EBAM metal 3D printers use high-value materials, such as titanium, tantalum, and nickel-based alloys, to produce parts and structures up to 20 feet in length. This award-winning process has produced large-scale parts significantly faster, cheaper and with less waste than traditional manufacturing methods for some of the largest aerospace companies in the world.

“Sciaky’s customers demand high quality, high-performance parts,” said Scott Phillips, President of Sciaky, Inc. “Hexagon’s Simufact solution helps increase confidence for our customers to ensure the best quality outcome.”

Hexagon and Sciaky unlock full potential of EBAM as Simufact DED process simulation optimizes EBAM process in G-code before depositionPrinting large parts composed of high-value metals can be tricky because material behaviors are tougher to predict for large geometries. To address this matter, Sciaky’s unique Interlayer Real-time Imaging and Sensing System (IRISS) enables closed-loop control of the EBAM 3D printing process to eliminate variations and improve its quality and production throughput by sensing and digitally self-adjusting metal deposition in real-time, with precision and repeatability.

To further support EBAM’s closed-loop control, Hexagon’s Simufact solution has been validated to accurately simulate the thermal-mechanical behavior of the DED process, enabling users to analyze thermal history, stresses, strains, and distortions throughout the process and optimize build setup and process parameters virtually before deposition. As a result, the software reads EBAM’s printer trajectories and process parameters directly, reducing the effort required to produce the simulation model. The entire process is streamlined because the G-code is directly compensated within the software.

“Our goal is to deliver process simulation solutions that enable manufacturers to perform predictive analyses for parts faster than the part can be physically built and measured,” said Jeff Robertson, business development – virtual manufacturing and costing solutions, Hexagon, “Not long ago, it took months to complete high-quality simulations for these types of additive processes, but through our collaboration, we now have the ability to make the same accurate predictions in days or hours, so the technology can facilitate the efficient use of Sciaky’s powerful additive capabilities for parts of any size or complexity.”

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Davide Sher

Since 2002, Davide has built up extensive experience as a technology journalist, market analyst and consultant for the additive manufacturing industry. Born in Milan, Italy, he spent 12 years in the United States, where he completed his studies at SUNY USB. As a journalist covering the tech and videogame industry for over 10 years, he began covering the AM industry in 2013, first as an international journalist and subsequently as a market analyst, focusing on the additive manufacturing industry and relative vertical markets. In 2016 he co-founded London-based 3dpbm. Today the company publishes the leading news and insights websites 3D Printing Media Network and Replicatore, as well as 3D Printing Business Directory, the largest global directory of companies in the additive manufacturing industry.

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