Knauf Industries Additive uses additive manufacturing to produce tools for particle foam (EPP) applications with integrated, component-near cooling. Thanks to a patented design, up to 80% of tool weight can be saved compared to conventionally manufactured alternatives.
At full capacity, Knauf designs and prints up to 180 tools per year. Every print job uses 3DXpert Mechanical Simulation to automatically compensate for process-induced deformations.
Achieving high geometrical accuracy in metal additive manufacturing is challenging, driven by two distinct deformation sources:
Melting and rapid solidification of each laser track introduces localized stress, leading to overall tension and displacement across the part.
Cumulative heat input causes the entire part to undergo repeated heating and cooling cycles, leading to macroscopic shrinkage and dimensional deviations beyond what inherent strain models alone can predict.
The new coupled thermo-mechanical simulation combines inherent strain analysis with thermal simulation to fully incorporate both micro-weld stresses and global thermal effects. The demonstrator was printed in 316L, a component approximately 100mm × 140mm × 100mm, with a simulated heat-up of up to 470°C.
Both specimens were printed in a single print job without previous trials or adaptation of simulation parameters — and without countermeasures like increased layer time or additional supports.
When both weld deformation and shrinkage are compensated for, most of the part achieves less than 0.1mm deformation — a result that previously required expensive countermeasures and extended print times.