Dimensional inaccuracy due to thermal deformation remains a primary challenge in industrial metal additive manufacturing. Two distinct physical phenomena drive this:
Rapid heating and cooling during melting creates cumulative residual stresses. As layers build upon each other, these stresses lead to global tension and distortion. Inherent strain simulation models are commonly used to predict and mitigate this effect.
During printing, the entire component undergoes significant heating and subsequent cooling. This global temperature fluctuation causes dimensional error distinct from weld-induced stress — and cannot be captured by inherent strain models alone.
Process modifications like interlayer wait times or additional supports can address macro-level effects, but they directly increase build time and reduce throughput — making them economically challenging for serial production.
Oqton's new thermo-mechanical feature unifies the previously independent Mechanical and Thermal Simulation modules. By coupling thermal and mechanical solvers, it creates a comprehensive simulation of the entire printing process, enabling a single optimized pre-deformed model that accounts for both sources of distortion.
Emerson and Oqton applied this simulation to a large, solid 316L demonstrator — build time over 20 hours. The simulation predicted significant thermal effects that an inherent strain model alone would miss:
Post-build metrology confirmed that the pre-deformed part printed without any additional interlayer wait times met specification tolerances — validating that integrated thermo-mechanical simulation can effectively compensate for both inherent strain and global thermal shrinkage in a single, first-time print.
The primary benefit for industrial applications: a more predictable, efficient, and cost-effective production workflow for complex metal AM components.