All Things Ansys 079: The State of Simulation for Additive Manufacturing

 

Published on: January 11th, 2020
With: Eric Miller & Brent Stucker
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by Brent Stucker, the Director of Additive Manufacturing at Ansys to discuss the innovative capabilities of the Ansys additive suite of tools and it’s impact on the effectiveness of 3D printing for manufacturing and design.

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

Listen:
Subscribe:

@ANSYS #ANSYS

Discussions on the Past, Present & Future of Optimizing Topology for Manufacturing – Webinar

Traditional design approaches don’t make the most of new manufacturing methods, like additive manufacturing, which are removing design constraints and opening up new possibilities. The optimal shape of a part is often organic and counterintuitive, so designing it requires a different approach.

Topology optimization lets you specify where supports and loads are located on a volume of material and lets the software find the best shape.

Kick off the year by learning about one of the most exciting advancements in modern design and manufacturing. Join experts from PADT and nTopology for an interactive roundtable discussion on the ins and outs of topological optimization.

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Understanding Honeycomb Structures in Additive Manufacturing – Three Papers from ASU and PADT

PADT is currently partnering with Arizona State University’s 3DXResearch group on exploring bio-inspired geometries for 3D Printing. As part of that effort, one of our engineers involved in the project, Alex Grishin, PhD, was a co-author on several papers that have been published during this project.

Below is a brief summary from Alex of each article, along with links.


An Examination of the Low Strain Rate Sensitivity of Additively Manufactured Polymer, Composite and Metallic Honeycomb Structures

PADT participated in the research with the above title recently published in the open-access online journal MDPI ( https://www.mdpi.com/1996-1944/12/20/3455/htm ). This work was funded by the America Makes Program under a project titled “A Non-Empirical Predictive Model for Additively Manufactured Lattice Structures” and is based on research sponsored by the Air Force Research Laboratory under agreement number FA8650-12-2-7230.

Current ASU professor and former PADT employee Dhruv Bhate was the Lead Investigator and wrote the original proposal. Dhruv’s research interests involve bio-inspired design (the study of structures found in nature to help inform human design efforts) and additive manufacturing. Dhruv is particularly interested in the bulk properties of various lattice arrangements. While investigating the highly nonlinear force-deflection response of various additively manufactured honeycomb specimens under compression, Dhruv discovered that polymer and composite honeycombs showed extreme sensitivity to strain rates –showing peak responses substantially higher than theory predicts at various (low) strain rates. This paper explores and quantifies this behavior.

The paper investigates hexagonal honeycomb structures manufactured with four different additive manufacturing processes: one polymer (fused deposition modeling, or material extrusion with ABS), one composite (nylon and continuous carbon fiber extrusion) and two metallic (laser powder bed fusion of Inconel 718 and electron beam melting of Ti6Al4V). The strain rate sensitivities of the effective elastic moduli, and the peak loads for all four processes were compared. Results show significant sensitivity to strain rate in the polymer and composite process for both these metrics, and mild sensitivity for the metallic honeycombs for the peak load.

PADT contributed to this research by providing ANSYS simulations of these structures assuming viscoplastic material properties derived from solid dog-bone test specimens. PADT’s simulations helped provide Dhruv with a proposed mechanism to explain why INSTRON compression tests of the honeycomb structures showed higher peak responses (corresponding to classical ultimate stress) for these specimens than the solid specimens.


Bioinspired Honeycomb Core Design: An Experimental Study of the Role of Corner Radius, Coping and Interface

PADT participated in the NASA-funded research with the above title recently published in the open-access online journal MDPI (https://www.mdpi.com/2313-7673/5/4/59/htm ). This work was guided by former PADT engineer and current ASU Associate Professor Dhruv Bhate.  Professor Bhate’s primary research interests are Bio-Inspired Design and Additive Manufacturing. It was only natural that he would secure a grant for this research from NASA’s  Periodic Table of Life ( PeTaL) project. To quote from the website, “the primary objective…is to expand the domain of inquiry for human processes that seek to model those that are, were or could be found in nature…”

This paper focuses on the morphology of bee honeycombs found in nature –the goal being to identify key characteristics of their structure, which might inform structural performance in man-made designs incorporating similar lattice structures. To this end, the paper identifies three such characteristics: The honeycomb cell corner radius, the cell wall “coping” (a localized thickening of the cell wall at the mouth of each cell seen in a lateral cross-section), and the cell array “interface” (a zigzag pattern seen at the interface of two opposing, or “stacked” arrays).

Most of this work involved material testing and measuring dozens of natural honeycombs (most coming from various museums of natural history found in the United States) at ASU’s state-of-the-art facilities. PADT  contributed substantially by verifying and guiding tests with simulation using the ANSYS suite of software.


A Comparison of Modeling Methods for Predicting the Elastic-Plastic Response of Additively Manufactured Honeycomb Structures

PADT participated in this research found in the reviewed article published in Proceedings of the 29th Annual International Solid Freeform Fabrication Symposium – An Additive Manufacturing Conference.

Figure 14. (left) 2D plane strain model with platens connected to honeycomb with frictional contacts and (right) close-up of an individual cell showing the mesh size as well as corner radius modeled after experimental measurements

The lead investigator was current ASU professor and former PADT employee Dhruv Bhate, whose research interests involve Bio-Inspired Design (the study of natural structures to help inform human design processes) and Additive Manufacturing. In this research, Dhruv investigates discrepancies between published (bulk) material properties for the Fused Deposition Modeling (FDM) of ABS honeycomb structures. The discrepancies arise as substantial differences between published material properties, such as Young’s Modulus and yield stress, and those determined experimentally from FDM dog-bone specimens of the same material (which he refers to as “member” properties).

Figure 4. (left) Homogenization enables the replacement of a cellular material with a solid of effective properties, (right) which can greatly reduce computational expense when simulating engineering structures

PADT’s role in this research was crucial for demonstrating that the differences in base material characterization are greatly exacerbated in nonlinear compression simulations of the ABS honeycomb structures. PADT used both the manufacturer’s published properties, and the dog-bone data to show substantial differences in peak stress under the two assumptions.

https://www.scopus.com/record/display.uri?eid=2-s2.0-85084948560&origin=inward&txGid=a19776da6deb7846e12bc8f7573181ab

6 – An update on outputting results in Ansys Mechanical: 3D Printing Results

To support some new marketing efforts I had to make some different types of results output from models in Ansys Mechanical:

  • A 3D plot on a webpage
    Post 5
  • A physical printout on our 3D Printer
    Post 6

All of the posts are here.

This post is the final, of six, and we finally get to the topic that we get the most questions on: “How do I convert my Ansys Results to a 3D Printed Model.” This article will cover taking Ansys Mechanical FEA results, stress, vibration, and heat transfer, and make a cool 3D plot on Stratasys full-color printers. The process should work on other color printers, but we have only tested it with Stratasys.

3D Printing and Color

Since the beginning of 3D Printing, we have been using a file format called STL. The format only contains the external surface of an object represented as triangles, and it does not support color. But there is good news, a new format, 3MF, or 3D Manufacturing Format was recently introduced to replace STL. It is one of several 3D formats that contain not only triangles on the surface of an object, but they support color information for each triangle. 3MF is for 3D Printing. PLY, OBJ, X3D, and others are for rendering and viewing.

But there is bad news. At this time (2020 R2), no Ansys products support 3MF. So we need to get our results into a format that Stratasys can read color data from, which is the latest version of OBJ. Because of this, we will use our favorite Ansys post-processor, EnSight, to create a PLY file, then an open-source 3rd Party tool, Meshlab, to make an OBJ.

Note 1: As soon as Ansys supports 3MF or OBJ or someone adds a 3MF/OBJ ACT Extension, we will update this article.

Note 2: The steps below are actually covered in the post in Post 2 on how to use EnSight and Post 5 on how to make usable 3D result files. But I’ll repeat them here since you may have only come to learn how to make a 3D result file.

Step 1: Get what you want to print as PLY in Ansys EnSight

Ansys Ensight is a powerful tool that does so much more than make 3D result files. But we will focus on this particular capability because we can use it to get our 3D Printed results.

In Post 2 of this series, I go over how to get a high-quality 2D image from EnSight. Review it if you want more details or if you run into problems following these steps.

Before we get going, one key thing you should know is that Ansys EnSight reads a ton of formats, and one of them is the result files from Ansys Mechanical APDL. So we will start with getting that file.

The program reads Ansys Mechanical APDL result files. These are created when you run Ansys Mechanical and are stored in your project directory under dp0/SYS/MECH and is called file.rst or file.rth. I like to copy the result file from that directory to a folder where I’m going to store my plots and also rename it so I know what it is. For our impeller model, I called it impeller-thin-modal-1.rst.

Once you have your rst file, go ahead and launch EnSight.

That brings up a blank sessions. To get started click File > Open

This will bring up a dialog box for specifying a results file. If you click on the “File type:” dropdown, you will see the long list of supported files it can work with. Take a look while you are there and see if any other tools you use are listed. Of course, Ansys FLUENT and CFX are in there.

But the one we want is Ansys Results (*.rst *.rth *.rfl *.rmg). Chose that, then go to the directory where you put your Ansys result file.

EnSight will read the file and put it in a Case. It will list the results as Part 0 under Case 1.

The left part of the screen shows what you have to work with, and the right shows your model. The “Time” control, circled in green, is where you specify what time, substep, or mode you want. The “Parts” control lets you deal with parts, which we really won’t use. And the “Variables” control, circled in orange, is how you specify what result you want to view.

We want to plot deflection, which is a vector. Click on the + sign next to Vectors, and you get a list of what values you can show. The only supported result for model analysis is Displacment__Vibration_mode. Click on that. Then hold down the right mouse button and select “Color Part” > All.

This tells the program to use that result to shade the part. You should now see your contour.

Our example is a modal result. If you use a structural result file, you will be able to plot the displacement vector, as well as many stress results, under “Scalars”

By default, EnSight shows an undeformed object. If you want to see the deflected shape, click on the part then on the “Displacement” icon above the graphics window. Select the vector result you want to use, displacement in this case. Note, the default displacement factor may not be a good guess, change that till you get the amount of deflection you want.

Note, the default displacement factor may not be a good guess, change that till you get the amount of deflection you want.

The other thing you may want to change is the contours. It has a full library of colors you can change to, but I like the default. What I don’t like is that the min and max may not be where I want them, especially for modal deflection results. The min and max values are the min and max in the result file, and unless you normalize your results, you should tweak the values for your 3D print.

Here is the default color scheme for my 40th mode:

To change the range, click on the contour key and Right-Mouse-Button on the legend, and select Edit… This brings up the Create/edit annotation (legends) dialog. Then click “Edit Pallet…” at the top of that dialog to get to the Pallete editor.

You can make lots of changes here, but what I recommend you do is only change the min and max values. If I set the max to 50, I get this contour on my result:

Next, we wan to save as PLY.

Go to File > Export > Geomtric Entities.

In the dialog, chose PLY Polygonal File Format. This will be the generic format we can convert into something GrabCad likes. Make sure you specify which times or modes you want. By default, it will make a PLY for each one. Also, make sure you have selected the part.

Now you have a color-coded, faceted representation of your results, in a 3D file format. Just not one that GrabCADPrint currently supports.

Step 2: Convert to OBJ in MeshLab

Now we need MeshLab. There are many other tools the read PLY files and output to other formats, but MeshLab has not let me down yet. It is opensource, does everything, and is a pain to use. You will laugh at the user interface. But as ugly as it is, it works. You can download MeshLab from www.meshlab.net. Once you have it installed, follow these steps:

  • Open MeshLab
  • Chose File > Import Mesh
  • Spin it around, look at it. You could scale and transform. But we just want to convert it.
  • Chose File > Export Mesh As
  • Scroll down in the File of Type dropdown and pick Alias Wavefront Object (*.obj)
  • Save
  • Make sure you have only Color checked for Vert. Then click OK

Here is an OBJ file from the example above.

That is it. Import that file into Stratasys GrabCAD Print and have at it.

I printed a different mode shape, but I think it looks fantastic. Click to get the full-resolution version.

Closing thoughts

And this ends our series on getting output from Ansys Mechanical, circa early 2021. It was just going to be one article on getting higher resolution images, but it grew a bit. We hope you find it useful.

Remember, PADT is here to help. We are proud to be an Ansys Elite Channel Partner offering Ansys products across the southwestern US.

PADT has been doing this for a while, and we can offer help in terms of one-on-one support, training, customization, and consulting services. Although this article focused on Ansys Mechanical, we cover the physics across the Ansys product line with experienced engineers in every area. And don’t forget we do 3D Printing as a service as well as product design.

Please contact us to learn more.

Optimize Additive Topology with FDM Fixture Generator – Webinar

Additive Manufacturing has profoundly impacted all aspects of manufacturing. With the ability to increase speed-to-market, lower production costs, and customize specialty parts, it continues to fuel innovation. Manufacturing jigs, fixtures, and other tooling accounts for more than 20% of all end-use parts produced with 3D printing today. Yet, without tools that make the design of custom jigs and fixtures simpler, many users are kept from reaching the full benefits of Additive Manufacturing on the factory floor.

One tool that is helping engineers bypass this roadblock is the latest collaborative effort from Stratasys and nTopology, the FDM Fixture Generator.

This innovative software tool allows you to automate the design of 3D printed jigs & fixtures. Generate custom designs and streamline operations on your factory floor without spending time in CAD. Ready to print with a few clicks.

Join nTopology and PADT to learn more about FDM Fixture Generator and how it stands to disrupt the manufacturing environment.

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Press Release: With New Capabilities in Metal 3D Printing, PADT Expands its Presence in the AM Value Chain

The world of Additive Manufacturing continues to evolve, and PADT’s offerings grow with those changes. Our latest advance is in the addition of a new system and an experienced engineer – an EOS M 290 and Keng Hsu, former ASU and Univeristy of Lousville professor. Read below to learn more.

We also have a PDF and HTML version of the release.

As always, if you have any questions, please contact us.


With New Capabilities in Metal 3D Printing, PADT Expands its Presence in the AM Value Chain

To Deepen its Investments in Metal Additive Manufacturing Research and Development, PADT Also Brought Onboard Veteran Engineer Keng Hsu as Principal AM R&D Engineer

TEMPE, Ariz., November 17, 2020 PADT, a globally recognized provider of numerical simulation, product development, and 3D printing products and services, today announced it has installed an advanced metal 3D printer from EOS, a global leader in the industrial metal 3D printing technologies, at its headquarters facility in Tempe, Arizona. With this increase in AM process and material capability, PADT can not only develop the highest quality end-use metal products, but also is well-positioned to address some of the current research and development challenges in additive manufacturing. PADT’s wide range of customers in highly demanding industries, most notably aerospace and defense, will see direct benefits of this new capability.

To lead metal additive manufacturing research and development (R&D), PADT also announced it has brought onboard Keng Hsu, engineer, researcher and associate professor at University of Louisville and formerly Arizona State University. Hsu brings more than 20 years of experience in equipment and facility operations, engineering R&D, engineering project execution and management in areas of advanced manufacturing of polymers, metals, and semiconductors. He has performed in-depth R&D contracts on 3D printing process and material development for some of the world’s largest technology organizations including Intel, Northrup Grumman, Salt River Project, the Department of Defense, and NASA.

“Metal 3D printing has reached a level of maturity that enables the production of end-use components and is now one of the fastest-growing manufacturing sectors in the world,” said Rey Chu, co-founder and principal, PADT. “The addition of the powerful EOS M290 printer to our portfolio expands the already extensive list of 3D printing capabilities and services we offer our customers. Our investments in technology and the addition of additive manufacturing veteran Keng Hsu also improves our ability to perform in-depth R&D on the potential of metal 3D printing.”

Dr. Keng Hsu

The EOS M 290 is a highly productive, and well-established mid-size AM system with a broad portfolio of metals for production of high-quality components, and for material and process R&D. PADT will initially run two of the machines most popular and versatile metals – stainless steel and nickel super alloy. The system also features a host of software tools, including its comprehensive monitoring suite, which enables quality assurance of all production- and quality-relevant data in real-time. Hsu will lead PADT’s R&D involved with the EOS machine and all other aspects of the company’s work in 3D printing R&D and consulting.

“The innovation made possible by metal 3D printing and in the technology itself is yet to be fully realized across many industries, namely aerospace,” said Hsu. “I’m grateful for the opportunity to join a leader in the industry and further my research on the subject to advance PADT’s presence in the field and services for our customers.”

PADT has been the Southwest’s premier additive manufacturing expert since it was founded in 1994 and continues to invest in innovative metal and polymer 3D printing systems, as well as talent, to better serve its customers. The company is ITAR registered and its quality system is also AS9100D (2016) and ISO9001:2015 certified to better serve the aerospace and defense industry. As an Ansys Elite Channel partner, PADT can also bring their extensive simulation experience to better design parts to take advantage of laser powder bed fusion and to optimize the build processes itself.

As 3D printing technology has advanced, PADT has seen an increase in the industry’s use of 3D scanning and printing for end-use parts. Metal 3D printing provides many benefits to aerospace and defense companies, including lighter, cheaper parts made much faster and with fewer constraints than with traditional manufacturing methods.

A full list of the EOS M 290’s specifications can be found on PADT’s website here . For more information on PADT and its capabilities in metal and plastic 3D printing, please visit www.padtinc.com.

About PADT

PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.

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Press Release: PADT Expands its Operations in New Mexico With the Addition of 3D Printing Talent and Services

New 3D Printing Field Service Engineer Brings Exceptional 3D Printing Tooling and End-Part Production Skills and Knowledge to the Region

We are very pleased to announce that one of our 3D Printer experts is relocating to our New Mexico facility. Art Newcomer has moved to Albuquerque and will continue to support our Colorado and New Mexico cusotmers from there instead of our Littleton Office.

Read more in the press release below or as a PDF or HTML.

As always, if you have any questions, please contact us.


PADT Expands its Operations in New Mexico With the Addition of 3D Printing Talent and Services

New 3D Printing Field Service Engineer Brings Exceptional 3D Printing Tooling and End-Part Production Skills and Knowledge to the Region

TEMPE, Ariz., October XX, 2020 PADT, the Southwest’s leading provider of numerical simulation, product development, and 3D printing products and services, today announced 3D printing expert Art Newcomer is relocating from the company’s Colorado office to its long-standing New Mexico facility, located in Sandia Science & Technology Park (SS&TP). The move comes on the heels of PADT’s expanded capabilities and services in 3D printing and numerical simulation in California and Texas. Combined, these recent moves bolster the company’s ability to serve the growing region.

“Art has done a fantastic job supporting our Colorado customers and has been a significant contributor to our growth in the state,” said Ward Rand, co-founder and principal, PADT. “As a member of the PADT support team, he will continue to serve Colorado customers. Art’s move to New Mexico simply expands his impact on a region that has seen a significant acceleration of 3D printing adoption, making his extensive knowledge and talents a real asset there moving forward.”

Newcomer has been serving PADT’s 3D printing customers for five years, and has nearly 20 years of experience as a field service engineer across different technologies and sectors. In his role at PADT, he applied his talents to help customers install, maintain, and repair their Stratasys additive manufacturing systems across a wide variety of industries including aerospace, defense, medical, and industrial.

PADT’s growing customer base in New Mexico has expanded the application of proven Stratasys 3D printing technologies to include more tooling and end-part production. The National Labs in New Mexico were pioneers in the application of 3D Printing and PADT has been proud to work with them over the years as they increase their efforts and find new applications for the technology.

“I’m looking forward to taking on a new challenge in New Mexico where PADT has served for many years,” said Newcomer. “The growth of 3D printing investments in the region provides us with a great opportunity to use our hard-earned expertise to educate customers on how to best implement the technology and to keep their systems operating at peak performance”

To learn more about PADT’s services in New Mexico as well as its continued expansion throughout the Southwest, please visit www.padtinc.com.

About PADT

PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.

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All Things Ansys 071: Structural Optimization & Additive Improvements in Ansys 2020 R2

 

Published on: September 8th, 2020
With: Eric Miller & Doug Oatis
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Lead Mechanical Engineer Doug Oatis for a discussion on what you can expect from the latest advancements in topology optimization and simulation for additive manufacturing, available in Ansys 2020 R2. This update spans a variety of areas, including optimizing setup, modifying STL files, parameter free morphing, and much more.

If you would like to learn more about this update, you can view Doug’s webinar on the topic here: https://www.brighttalk.com/webcast/15747/433058

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

Listen:
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@ANSYS #ANSYS

Press Release: Stratasys Platinum Channel Partner PADT Expands 3D Printing System Sales Into Texas to Meet the Growing Demand for Prototyping and End-Use Products

Demand for 3D Printing Equipment and Services in Texas’ Key Technology Industries Including Aerospace, Electronics, and Medical Has Drastically Increased

As a Platinum Channel Partner with Stratasys, PADT is excited to announce that we are now able to offer these services in Texas. We have been working with this technology in Arizona, Colorado, New Mexico, and Utah for more than 15 years, and are eager to finally bring our expertise to customer in the great state of Texas. 
 


This expansion is reflective of PADT’s consistent growth and the increased demand for additive manufacturing systems across many of Texas’ largest technology industries. Today, the aerospace industry is using thousands of 3D printed parts on aircraft and even spacecraft.

With PADT’s knowledge and expertise, we are well-positioned to be a valuable partner to the growing tech community in Texas. 

Please find our official press release below, or here as a PDF or in HTML.


Stratasys Platinum Channel Partner PADT Expands 3D Printing System Sales Into Texas to Meet the Growing Demand for Prototyping and End-Use Products

Demand for 3D Printing Equipment and Services in Texas’ Key Technology Industries Including Aerospace, Electronics,
and Medical Has Drastically Increased

TEMPE, Ariz., August 12, 2020 PADT, a globally recognized provider of numerical simulation, product development, and 3D printing products and services, today announced its Stratasys sales territory is expanding to include Texas. PADT is a Stratasys Platinum Channel Partner that has sold additive manufacturing systems as a certified reseller in Arizona, Colorado, New Mexico, and Utah for more than 15 years. In 2018, PADT also expanded its presence to Austin, Texas as a reseller of Ansys simulation software.

“Additive manufacturing technology that was once exclusive to low-volume prototyping has evolved rapidly for both prototyping and end-use product development alongside innovation in Stratasys’ 3D production systems and printing materials,” said Ward Rand, co-founder and principal, PADT. “We’ve made deep investments in Texas and have many years of experience working with organizations in the state’s technology industry. We’re now eager to bring our outstanding support and expertise in 3D printing to Texas and build on our success with Stratasys and Ansys across the Southwest.”

The expansion is reflective of PADT’s consistent growth and the increased demand for additive manufacturing systems across many of Texas’ largest technology industries. Today, the aerospace industry is using thousands of 3D printed parts on aircraft and even spacecraft. In the medical industry, 3D printing is being used to prototype biological structures to improve surgery and enhance our knowledge of the human body. Stratasys has been a driving force behind this innovation and relies on industry experts like PADT to help organizations integrate the technology into their engineering and manufacturing processes.

“PADT has been an outstanding partner to Stratasys for nearly 20 years,” said Brent Noonan, Vice president of Channel Sales – Americas. “They were one of the first engineering firms in the country to embrace 3D printing for complex product design and development. As a result, they’ve built an impressive team with a wealth of knowledge and expertise as it relates to 3D printing use and integration across industry sectors. PADT is well-positioned to be a valuable partner to Texas’ growing technology community.”

For more information on PADT and its 3D printing offering, please visit www.padtinc.com.

About PADT

PADT is an engineering product and services company that focuses on helping customers who develop physical products by providing Numerical Simulation, Product Development, and 3D Printing solutions. PADT’s worldwide reputation for technical excellence and experienced staff is based on its proven record of building long-term win-win partnerships with vendors and customers. Since its establishment in 1994, companies have relied on PADT because “We Make Innovation Work.” With over 90 employees, PADT services customers from its headquarters at the Arizona State University Research Park in Tempe, Arizona, and from offices in Torrance, California, Littleton, Colorado, Albuquerque, New Mexico, Austin, Texas, and Murray, Utah, as well as through staff members located around the country. More information on PADT can be found at www.PADTINC.com.

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From visualization to simulation: Digital Anatomy Solutions for 3D Printing – Webinar

The Stratasys J750 Digital Anatomy printer truly brings the look and feel of medical models to life with unrivaled accuracy, realism and functionality. Whether used for surgeon training or to perform testing during device development, its models provide unmatched clinical versatility mimicking both the appearance and response of human tissue.

Bring medical models to life. The J750 Digital Anatomy Printer takes the J750 capabilities to the next level. Step up to the printer’s digital capabilities to create models with an incredible array of microstructures which not only look, but now feel and function like actual human tissue for true haptic feedback. All of this in a single print operation with minimal to no finishing steps like painting, sanding or assembly.

Join PADT’s 3D Printing & Support Application Engineer Pam Waterman for a discussion on the value of this innovative new technology, including:

– How it solves challenges facing medical device companies and hospitals

– More realistic, functional, and anatomically accurate modeling capabilities

– Quicker design and development, leading to reduced time-to-market

– And much more

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Top Ten Additive Manufacturing Terms to Know

The world of additive manufacturing, or 3D printing, is constantly evolving. The technology was invented less than 35 years ago yet has come a long way. What began as a unique, though limited, way to develop low-end prototypes, has exploded into a critical component of the product development and manufacturing process with the ability to produce end-use parts for critical applications in markets such as industrial and aerospace and defense. Trublutint can guide about manufacturing in a better way.

To help our customers and the larger technology community stay abreast of the changing world of additive manufacturing, we launched a glossary of the most important terms in the industry that you can bookmark here for easy access. To make it easier to digest, we’re also starting a blog series outlining ten terms to know in different sub-categories.

For our first post in the series, here are the top ten terms for Additive Manufacturing Processes that our experts think everyone should know:

Binder Jetting

Any additive manufacturing process that uses a binder to chemically bond powder where the binder is placed on the top layer of powder through small jets, usually using inkjet technology. One of the seven standard categories defined by ASTM International (www.ASTM.org) for additive manufacturing processes.

Digital Light Synthesis (DLS)

A type of vat photopolymerization additive manufacturing process where a projector under a transparent build plate shines ultraviolet light onto the build layer, which is against the transparent build plate. The part is then pulled upward so that a new layer of liquid fills between the build plate and the part, and the process is repeated. Digital light synthesis is a continuous build process that does not create distinct layers.

Direct Laser Melting (DLM) or Direct Metal Laser Sintering (DMLS)

A type of powder bed fusion additive manufacturing process where a laser beam is used to melt powder material. The beam is directed across the top layer of powder. The liquid material solidifies to create the desired part. A new layer of powder is placed on top, and the process is repeated. Also called laser powder bed fusion, metal powder bed fusion, or direct metal laser sintering.

Directed Energy Deposition (DED)

An additive manufacturing process where metal powder is jetted, or wire is extruded from a CNC controlled three or five-axis nozzle. The solid material is then melted by an energy source, usually a laser or electron beam, such that the liquid metal deposits onto the previous layers (or build plate) and then cools to a solid. One of the ASTM defined standard categories for additive manufacturing processes.

Fused Deposition Modeling (FDM)

A type of material extrusion additive manufacturing process where a continuous filament of thermoplastic material is fed into a heated extruder and deposited on the current build layer. It is the trademarked name used for systems manufactured by the process inventor, Stratasys. Fused filament fabrication is the generic term.

Laser Powder Bed Fusion (L-PBF)

A type of powder bed fusion additive manufacturing process where a laser is used to melt material on the top layer of a powder bed. Also called metal powder bed fusion or direct laser melting. Most often used to melt metal powder but is used with plastics as with selective laser sintering.

Laser Engineered Net Shaping (LENS)

A type of direct energy deposition additive manufacturing process where a powder is directed into a high-energy laser beam and melted before it is deposited on the build layer. Also called laser powder forming.

Material Jetting

Any additive manufacturing process where build or support material is jetted through multiple small nozzles whose position is computer controlled to lay down material to create a layer. One of the ASTM defined standard categories for additive manufacturing processes.

Stereolithography Apparatus (SLA)

A type of vat photopolymerization additive manufacturing where a laser is used to draw a path on the current layer, converting the liquid polymer into a solid. Stereolithography was the first commercially available additive manufacturing process.

Vat Polymerization

A class of additive manufacturing processes that utilizes the hardening of a photopolymer with ultraviolet light. A vat of liquid is filled with liquid photopolymer resin, and ultraviolet light is either traced on the build surface or projected on it. Stereolithography is the most common form of vat photopolymerization. The build layer can be on the top of the vat of liquid or the bottom. One of the ASTM defined standard categories for additive manufacturing processes.

We hope this new blog series will help to firm up your knowledge of the ever-evolving world of additive manufacturing. For a list of all of the key terms and definitions in the additive manufacturing world, please visit our new glossary page at https://www.3dprinting-glossary.com/. The glossary allows you to search by terms or download a PDF of the glossary in its entirety to use as a reference guide.

We also know that there are a ton of experts in our community with knowledge to share. If you notice a term missing from our glossary or an inaccurate/incomplete description, please visit the suggestions page at https://www.3dprinting-glossary.com/suggest-a-correction-clarification-or-new-term/ and drop us a note.

Subscribe to the PADT blog or check back soon for the next installment in our series of “Top Ten Terms to Know in Additive Manufacturing.” We also welcome your feedback or questions. Just drop us a line at here.

Combining Simulation with Additive Manufacturing to Optimize Product Design – Webinar

Advatech Pacific, a Phoenix-based aerospace and defense contractor founded in 1995, works to change the way engineering is conducted for the better by incorporating innovative technologies into its customer’s workflow. Based on the success of previous projects, Advatech is a strong proponent of using high-end simulation software such as Ansys to identify and evaluate the fine details of massive multi-body mechanical systems, whether through simple static analyses or tightly-coupled multiphysics computations.

Implementing additive manufacturing as an additional way to improve system design presented opportunities to cut back on tooling costs and reduce lead time for several candidate turbine-engine parts. Doing so would also alleviate the challenge of reproducing complex castings, a problem made increasingly difficult by the fact that many of the original casting providers are no longer in business.

Join PADT’s Lead Mechanical Engineer Doug Oatis, and Advatech Pacific’s Engineering Manager Matt Humrick for a discussion on Ansys tools with regards to additive manufacturing & topology optimization, and how Advatech Pacific was able to use them to drastically improve the efficiency of their design and manufacturing process.

Register Here

If this is your first time registering for one of our Bright Talk webinars, simply click the link and fill out the attached form. We promise that the information you provide will only be shared with those promoting the event (PADT).

You will only have to do this once! For all future webinars, you can simply click the link, add the reminder to your calendar and you’re good to go!

Five Ways to Save Time and Money in Your Product Development Process Using the Stratasys J55

Is your current prototyping process costing you more time and money than it should?

Bring higher quality modeling in-house at your team’s elbow, and straight into the design process. Using traditional production methods is costing your product development teams time and money.

Quality model shops have a long queue and large price tag, traditional modeling by hand is laborious and time consuming, and outsourcing comes with a laundry list of communication headaches, IP theft concerns, and extra costs.


Ready to learn more?


Make communication easier, improve design quality, and reduce time to market.

Click the link below to download the solution guide and discover five ways the Stratasys J55 can help you save time and money during the product development process. 

Download Here

Introducing the Stratasys J55 3D Printer – Possibilities at Every Turn

From perfecting products to applying concepts learned in the classroom, Stratasys can help you realize any number of design ideas. The new J55 introduces a rotating print platform for outstanding surface finish and printing quality, and features multimaterial capabilities and material configurations for both industrial and mechanical design.

The Stratasys J55 3D Printer is a huge leap forward for accessible, full color 3D printing and allows designers to have multiple iterations of a prototype ready and at their fingertips throughout every phase of the design process.

Enhanced 3D printing capabilities include – static print head, rotating build tray, UV LED illumination technology, new material cartridge design, and more. The full reliability and quality of PolyJet technology created for an office or studio environment, at an affordable price.

Designed for consistent, stable performance, the J55 requires zero mechanical calibrations and features a “ready-to-print” mode, so you can make ideas a reality without interruption.

Click the link below to download the product brochure and learn how this innovative new machine is revolutionizing the world of additive manufacturing. 

All Things Ansys 062: Optimizing Materials Selection for Additive Manufacturing with Ansys Granta

 

Published on: May 4th, 2020
With: Eric Miller, Pam Waterman & Robert McCathren
Description:  

In this episode your host and Co-Founder of PADT, Eric Miller is joined by PADT’s Pam Waterman and Robert McCathren for a discussion on how Ansys Granta can be used to help optimize hardware selection for additive manufacturing. The Senvol Database details 1,000 AM machines and more than 850 compatible materials. Using this tool within Granta Selector, you can search and compare materials based on properties, type, or compatible machines.

If you would like to learn more about the Ansys tool and it’s applications for additive, check out our webinar on the topic here: https://bit.ly/2SAZN8G

If you have any questions, comments, or would like to suggest a topic for the next episode, shoot us an email at podcast@padtinc.com we would love to hear from you!

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