Ascent AM · Project

Simulation Software That Predicts 3D Metal Printing Defects Before You Print

manufacturingTestedTRL 5

mw.tum.de

Imagine you're 3D-printing a jet engine part from metal powder — it takes hours, costs thousands, and sometimes the finished piece warps so badly you have to scrap it and start over. This team at TU Munich built simulation software that predicts exactly how a metal part will deform during printing, so you can correct the design before hitting "print." Think of it like a spell-checker for manufacturing: it catches the errors before they become expensive mistakes. They also got the calculation speed down to match actual printing time, so it's fast enough to use in real production workflows.

By the numbers

up to 30%

CO2 and fuel burn reduction targeted by Clean Sky 2

up to 40%

NOX reduction targeted by Clean Sky 2

EUR 699,375

EU contribution to the project

Total project deliverables

Consortium partners (TU Munich only)

The business problem

What needed solving

Metal 3D printing (laser beam melting) of complex parts — especially for aerospace — is expensive and unpredictable. Parts often warp during production, leading to costly reprints and long trial-and-error development cycles. Existing simulation tools are either too slow to be practical or fail to account for post-processing effects like stress relief annealing.

The solution

What was built

The team built a simulation-based process chain for predicting distortions in laser beam melting. Key deliverables include calculation acceleration methods that bring simulation time down to or below actual build time, the ability to simulate multiple components on a build platform with mutual influence, and handling of complex filigree structures with very high finite element numbers. The project produced 9 deliverables in total.

Audience

Who needs this

Aerospace parts manufacturers using metal additive manufacturingMedical implant companies producing custom metal devices via laser beam meltingAM service bureaus offering metal 3D printing to multiple industriesAutomotive suppliers transitioning high-value components to additive manufacturingCAE/simulation software companies looking to integrate AM distortion prediction

Business applications

Who can put this to work

Aerospace manufacturing

enterprise

Target: Aero engine parts manufacturers using laser beam melting

If you are an aerospace manufacturer dealing with costly reprints when metal 3D-printed turbine components warp after production — this project developed simulation software that predicts distortions before printing, enabling first-time-right production. The tool was designed for laser beam melting of aero engine parts, with calculation times brought down to the range of actual building time. This directly reduces scrap rates and shortens your process development cycle.

Medical devices

mid-size

Target: Manufacturers of custom metal implants and surgical instruments via additive manufacturing

If you are a medical device company producing patient-specific metal implants through laser beam melting and struggling with post-production distortions — this project built a simulation-based process chain that predicts part warping with high accuracy. The software handles complex, filigree structures with very high element numbers, which is exactly what intricate implant geometries demand. It also accounts for post-processes like stress relief annealing, giving you a complete picture before production.

Industrial tooling and automotive

any

Target: Companies producing metal tooling inserts or automotive components via powder bed fusion

If you are a tooling or automotive supplier investing in additive manufacturing but losing money on failed builds due to unpredictable distortions — this project created simulation tools integrated into the AM process preparation workflow. The technology targets laser beam melting, the most widespread metal 3D printing method, and was designed to enable first-time-right production. With calculation time matching or beating building time, it fits into real production schedules without slowing you down.

Frequently asked

Quick answers

What would this simulation software cost to implement?

The project does not disclose licensing or pricing information. The software was developed at TU Munich with EUR 699,375 in EU funding under Clean Sky 2. Commercial terms would need to be negotiated directly with the university's technology transfer office.

Can this handle industrial-scale production volumes?

The demo deliverable confirms that calculation of multiple components on a single building platform — including their mutual influence — has been demonstrated. Calculation time was brought to the range of or lower than actual building time, which suggests it can keep pace with production schedules.

What is the IP situation and how could we license this?

The project was funded under Clean Sky 2 (CS2-RIA), which typically means IP stays with the consortium — in this case TU Munich as the sole partner. Licensing discussions would go through TU Munich's technology transfer office. Based on available project data, no commercial licensing arrangements are mentioned.

Does the simulation account for post-processing steps?

Yes. The project objective explicitly states that current simulation models fail to account for post-processes such as stress relief annealing, and that addressing this gap was a core goal. The simulation-based process chain was designed to include these post-processing effects in its distortion predictions.

What materials and processes does this cover?

The main focus is on laser beam melting (LBM) of metal powders, described in the project as the most widespread approach to generating three-dimensional parts from powder material. The project does not mention validation on specific alloys, so material coverage would need to be confirmed with TU Munich.

How accurate are the distortion predictions?

The project objective targets 'prediction of distortions with high accuracy in reasonable time.' The demo deliverable confirms the calculation acceleration methods were demonstrated, but specific accuracy percentages or tolerance ranges are not disclosed in the available data.

Is this ready to deploy in our production environment today?

The project ended in January 2020 and was conducted entirely at TU Munich without industrial consortium partners. While calculation methods were demonstrated, further integration and validation in a production environment would likely be needed before deployment. Contact TU Munich to learn about current development status.

Consortium

Who built it

This is a single-partner project run entirely by TU Munich, one of Germany's top technical universities with strong engineering credentials. The consortium has zero industrial partners and zero SMEs, which means the technology was developed in an academic setting without direct industry validation or co-development. For a business considering this technology, that means you would be the first industrial user — there is no track record of factory-floor deployment. On the positive side, dealing with a single university simplifies licensing negotiations. The project operated under Clean Sky 2 with EUR 699,375 in funding, focused specifically on aero engine applications.

TECHNISCHE UNIVERSITAET MUENCHENCoordinator · DE

How to reach the team

TU Munich, Institute for Machine Tools and Industrial Management (iwb). Contact through university technology transfer office or the iwb department directly.

Order a report on this consortium See TECHNISCHE UNIVERSITAET MUENCHEN profile →

Next steps

Talk to the team behind this work.

Want an introduction to the Ascent AM research team at TU Munich? SciTransfer can arrange a direct meeting to discuss licensing, collaboration, or custom development for your specific AM application.

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