2. DED Process Simulations

Enhancements for directed energy deposition (DED) simulations include the following:

Additive DED Add-in in the Discovery™ Application

Introduced at the last release, Discovery's Additive DED add-in allows you to generate geometry models directly from a tool path file, such as G-code. This Path to Part method offers more accurate views of print characteristics, like deposition volume and geometric feature details, compared to using nominal CAD designs. More functionality has been added to the add-in at this release:

  • Import CLS file format (Beta): You can now import a file in a Cutter Location Source (CLS) format. Specify the Paint Index used for deposition.

  • Multiple machine types supported: You can now specify either a Three-axis or Multi-axis machine in the Path tool. Inputs for Multi-axis machine include X-axis Rotation, Y-axis Rotation, Z-axis Rotation, Rotation Sequence, and Tool Direction.

  • Export material orientation from tool path file: You can now easily export material orientation data directly from the G-code/CLS file into the Mechanical application. This new function exports the Euler angles at every path point into a .CSV file. In the Mechanical application, this data is used to define local coordinate systems, which are necessary for applying realistic anisotropic (direction-dependent) material properties to your simulated part. The Interpolation Distance input is available to automatically generate interpolated points, achieving a finer resolution of local coordinate systems than the defined path points provide.

  • Visualization of tool path orientation: A new object called Tool Path is added to the tree upon import of your G-code or CLS file (Beta). This object stores the complete tool path and the specific orientation of the printer head at every position. Beyond viewing path curves, you can now visualize the deposition direction at any point—a critical feature for accurately interpreting how the bead profile is applied throughout the build.

  • New bead profiles added: When using the Path to Part tool, in addition to the standard Circular bead cross section, you can now specify a Rectangular or an Elliptical bead profile.

  • Scripting supported: You can now use Discovery's Script Editor to automate the workflow steps when using the Additive DED add-in. Record the steps in the workflow, adjust parameters as desired in the Script Editor, and replay the script any time. This technique allows you to customize the bead profile beyond the provided profiles (Circular, Rectangular, or Elliptical). Simply change the coordinates in the profile line of code in the script.

DED Process Add-on in the Mechanical Application

  • Multi-material deposition: You can now simulate deposition of multiple materials by simply defining distinct bodies and assigning the desired materials.

  • Hotspot result item: A new Hotspot result item has been added for calculating residual hotspots in the DED process. The hotspot shows the maximum temperature in each depositioned cluster of elements immediately before the next cluster is activated.