Optimising Performance and Manufacturability for Ingredient Manufacturing

by Kent Williams

Alexander Pluke, CEO, Additive Circulation

As this decade advances, the drive towards making use of AM as a substitute for traditional manufacturing modern technologies for essential applications is set to proceed, and will mainly be concentrated on brand-new and existing applications where making use of AM brings a considerable ROI throughout the value chain by lowering the general time and price of production. As a general rule of thumb, for AM to be utilized as an efficient manufacturing technology for any offered application it needs to show– as a minimum– a 10-fold renovation in cost and/or time financial savings to balance out the cost and also threat connected with transforming from a traditional production procedure chain.

There are applications in the general public domain name today that demonstrate this sort of ROI as well as worth, There are pointers that there are a lot more in R&D, yet to be revealed publicly as well as there are considerably more that have not been thought about yet. Because like AM is as a solution within its particular niche (and also it is still a particular niche within the worldwide context of production) there are still obstacles to adoption that are stalling uptake and growth of AM.

A vital barrier to adoption is the disconnect within the required process for AM. Just consider for a moment, the electronic tools needed for the physical outcome from an AM process. AM is extensively considered an electronic production device, rightly so. It’s likewise often pointed out as a necessary element of Sector 4.0. Aside from popular buzzwords, what are we really attempting to attain here? This is the crux of the conversation, in my opinion. Any offered AM system is simply one part within an intricate digital workflow that includes the creation (style), optimization, control and also simulation of data. Succeeding to these techniques, the data have to then be exchanged a machine-readable type by way of the “slicers or build processors” prior to attaining the physical goal– the necessary component( s). Even at the initial stage, the creation of the layout information, there are myriad options of standard parametric design software services, along with brand-new generative design alternatives that assist in kind and capability optimisation. Similarly, for design optimization as well as digital component simulation there are several other options. the data required for a successful AM component will travel through many different phases on its journey. This journey is presently complicated and needs serious expertise to navigate effectively via the different, frequently discrete, electronic devices.

It is necessary to clear up a juxtaposition on intricacy right here.

AM allows intricacy particularly in regards to part geometry and the physical structure of intricate forms that are not feasible with conventional manufacturing techniques. Without a doubt this is a positive USP of AM compared to standard production approaches. However, the digital process called for to help with AM applications vomits levels of complexity that can ban adoption, and this is a real obstacle and it calls for a brand-new strategy.

The “great” complexity has caused innovative as well as improved degrees of creativity as well as advancement for AM applications, where unprecedented degrees of style flexibility have led to new layout approaches for geometrically complex products. As mentioned there is now a variety of examples of generative style software components that can create latticework frameworks as well as topologically optimised structures for optimal performance and light-weighting benefits.

It is within this narrow scope that the general discussion around optimisation for AM applications often lies. I think it must be included understand the unrealized possibility of AM.


It is reasonable to state today that when the AM area speak about optimization, they are typically referring to create optimisation. Topology optimisation, as an example, looks for to attain the very best possible style for a framework by transforming worldly distribution within the layout space in order to achieve necessary functionality as well as optimize efficiency. Likewise, the proliferation in the (generative or otherwise) style of lattice frameworks, the production of which is but enabled by AM, has the potential to supply applications with new functionality consisting of high levels of energy absorption and stiffness, while at the same time offering light-weighting advantages and also reduced material usage. These are both favorable benefits of brand-new layout assuming that are driving brand-new and/or improved applications of AM. It goes without claiming that optimization continues to be imperative as an electronic style discipline, yet what I am saying is that it needs to be gone on, with a much more holistic technique and more linked electronic tools that can use a multi criterion approach all at once.

This way, a much more holistic approach requires smart and multi-functional digital tools that can optimize the layout geometry, product placement as well as AM procedure specifications in a single environment– essentially permitting developers and designers to optimize their entire electronic operations as well as eliminate the undesirable intricacies from it. This ability will certainly open the following degree of efficiency from AM and also industrial 3D printing modern technologies. The rationale behind this is the foundation of Additive Circulation and the advancement of our modular and multi-functional software program designed to simplify the electronic process chain, eliminate complexity, and also include actual value to AM applications.


Adopting a multi-functional as well as all natural method, we have actually created a flexible set of digital tools that can simultaneously take into consideration product residential or commercial properties, geometry and also material placement, equipment systems, as well as construct parameters. This raises multi-property performance as well as optimises the end results for AM applications, suitable throughout material systems (metal/polymer/ceramic) and mixes for compatible multi-material applications, within the boundaries of product scientific research where specified materials and also product residential properties can be integrated through the manufacturing process. We have actually achieved this with a multi-physics, multi-property topology optimisation strategy.


To address usual difficulties experienced within the Style for Additive Manufacturing (DfAM) operations and pre-production preparation, FormFlow is a broader kind of optimisation software program that integrates several one-of-a-kind functionalities allowed by certain physics-driven comparisons of the style, material, AM procedure parameters, and manufacturing output against key performance indicators (KPIs) as specified by details application top priorities.

These capabilities supply substantial time- and cost-efficiencies to the whole digital process as well as go well past the common capacities of distinct generative style, topology optimization, as well as style simulation software devices, while including every one of these capabilities.

In other words, FormFlow puts the right product, with the right buildings, in the right location; optimises part geometry and also material residential properties at the same time; ultimately allows users to at the same time check out productivity, price, as well as efficiency of various products, several products, and also various geometry optimizations; and also quickly as well as efficiently produces optimised production files according to multiple user-defined parameters.

Moreover, FormFlow is AM-process agnostic with specialist solvers that account for the unique properties in AM materials and can be tailored to work with single- and/or multi-material designs.

I believe we are the first company to commercially offer these simultaneous capabilities to maximise performance and manufacturability for additive manufacturing.


Additive Flow’s FormFlow solution addresses some inherent characteristics within AM processes that can be easy to overlook. For example, AM processes in general exhibit variations in physical properties along the build axis (anisotropy), where the 3D printed part behaves differently depending on the direction of force applied to it. This usually means that 3D printed parts behave differently to forces applied perpendicular to the build direction.

If these are ignored, or the standard isotropic solvers on the market are used, optimisation results will invariably be wrong, and in such a way key safety factors may be missed and/or true optimisation opportunities lost. This anisotropy plays an even greater role within composite structures, where fibre orientation delivers enhanced engineering properties in particular directions. The solvers within FormFlow ensure that the opportunities for anisotropic optimisation can be realised for every application.

AM also allows for the adjustment of parameters throughout the printing process, or the application of different parameters to different regions of a part. This has the potential to unlock productivity, cost, and performance improvements when compared with traditional manufacturing processes.

However, the complexity of manually deciding which regions should have which property sets can be time-consuming and complex. FormFlow addresses this through the use of multi-property optimisation algorithms, the software having the capability to address different parameter sets within an optimisation while enabling skilled engineers to apply their parameter knowledge seamlessly across a split mesh.


Additive Flow is working on a project consultancy basis with myriad companies from OEMs to SMEs and AM ecosystem players. This is enabled by the modular architecture of our software, and can be deployed across customised workflows with all of its multi-functionality, or it can be applied specifically to unlock particular bottlenecks in any given workflow.

As well as bringing modular and scalable multi- functional digital solutions to the market that can be customised to specific applications, at the heart of Additive Flow is sustainability in modern day product development and manufacturing environments. The company was founded on the principle of disrupting AM for an improved world by focusing on reducing manufacturing impact on the environment; enabling sustainable designs an

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