Goodbye Guesswork: The Magic Behind Flow PanX Simulation Software

March 25, 2024

In metal additive manufacturing (AM), achieving first-run print success while minimizing the risk of build issues is challenging. With larger build volumes and new alloys, even the experience of senior engineers can be insufficient to eliminate every problem. PanOptimization represents a leap forward in this regard, granting the ability to conduct pre-build simulations directly on the build file for large print volumes. What’s even more exciting is that Velo3D now has a direct integration with PanOptimization’s PanX software to raise the level of predictability and efficiency for modern metal AM.

Export your PanX input files directly from Flow to receive detailed and highly accurate simulation results. Import adjustments from PanX and avoid issues with translation or manual build set up.

The Core of PanX Integration

At the heart of this integration is the PanX software, a standalone platform designed to simulate and optimize the thermomechanical behavior of printed parts. By identifying potential thermal and mechanical build issues before printing, PanX allows for the optimization of print instructions, ensuring a higher rate of first-run success. This not only saves time and resources but significantly reduces the need for costly test prints.

The Power of Simulation

The true power of PanX lies in its simulation capabilities. Utilizing Multi-Grid Modeling, the software computes high-accuracy temperatures, stresses, and distortions in a fraction of the time it would take to physically build the part. This capability is particularly beneficial for parts with complex geometries or those made from thermally challenging materials. By adjusting laser power and other parameters within the print file, PanX helps achieve successful prints without the need to alter the established print parameters fundamentally.

Dwell optimization enables users to target delays to prevent overheating issues without adding unnecessary build time. As an added benefit, this kind of optimization is the easiest to certify, as the process parameters are unchanged.

Streamlining the Workflow

One of the most compelling aspects of the PanX integration is its direct connection with Velo3D’s Flow print-preparation software. Users can export their PanX input files directly from Flow, ensuring that the simulation results are based on exact print and parameter instructions. This direct integration streamlines the workflow, enabling engineers to import optimized print instructions back into Flow without the hassle of manual setup or translation issues.

Addressing Complex Challenges

PanX’s capabilities extend to modeling complex materials and large builds. The software efficiently generates Finite Element Analysis (FEA) meshes and resolves fine features, even in full build volume (diameter 600 mm x 1,000 mm z-height) parts. This is particularly advantageous for builds with thin walls or those involving materials with high melt temperatures or stress concentrations.

Quickly and efficiently generate FEA meshes and resolve fine features even on full build volume parts. Compute high accuracy temperatures, stresses, and distortions for thin walls or builds in materials with high melt temperature or high stress concentrations.

The Broader Velo3D Ecosystem

The integration of PanX into the Velo3D ecosystem is more than just a technical enhancement; it’s a strategic addition to Velo3D’s fully integrated manufacturing solution. This ecosystem empowers engineers to build and scale mission-critical parts with production worthy precision and reliability.

If you’d like more details on the different elements of our fully integrated manufacturing solution, we have some excellent resources on Sapphire, Flow, and Assure.

Beyond the Software

The collaboration between Velo3D and PanOptimization extends beyond software integration. PanOptimization’s ongoing development efforts aim to further refine the predictive capabilities of the software, addressing even more complex geometries and manufacturing scenarios. This continued innovation holds the promise of significant cost and time savings by further reducing the reliance on physical trial and error in metal printing.

Empowering Success in Metal AM

The integration of PanX with Velo3D’s Flow software is a testament to the power of collaboration and innovation in metal additive manufacturing. By offering a more predictable and efficient path from design to production, Velo3D and PanOptimization are not just solving technical challenges but are opening up new possibilities for engineers and manufacturers worldwide.

Looking for more insights into how Flow and PanOptimization software work together? Check out Episode 36 of our 3Din30 LinkedIn Live series, “From Art to Science – Foolproofing Your Metal AM Process.” This episode dives into the predictive power of PanOptimization software, showcasing its ability to optimize printing through detailed simulations that mitigate build failures and featuring real-world examples and discussions on how this technology boosts the success rate and predictability of complex metal prints.

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About the Author

Amir Iliaifar

Director of Content

Amir Iliaifar is the Director of Content at Velo3D where he oversees the production and distribution of Velo3D’s global digital content marketing initiatives. Prior to joining the company, Amir worked for a leading professional drone manufacturer, several SaaS companies, and as an automotive tech journalist. He holds a Master of Arts in Digital Communication from the University of North Carolina at Chapel Hill.