Reimagine Metal Additive Manufacturing with Virtual Precision

Metal Additive Manufacturing (AM) continues to transform how components are designed and produced - but process-induced defects often limit its full potential.

Join Hexagon’s expert-led session to explore how Simufact Additive’s new Powder Bed Fusion (PBF) Process and Defect Analysis (PDA) module brings unprecedented visibility into metal 3D printing.
 

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Hexagon’s Simufact Additive PDA module leverages a multi-scale hybrid model to predict the type and location of fusion defects with remarkable accuracy.

From lack of fusion and keyhole formation to surface roughness, the solution helps engineers visualize - and eliminate - potential issues long before they appear on the build plate.

Key takeaways

 

 
Advanced fusion defect prediction

The PDA module uses a multi-scale, hybrid model to predict the location and type of fusion defects in L-PBF parts with high accuracy. Defects like lack of fusion, keyhole formation, balling and surface roughness etc. 		  Process Optimization

Virtually tune laser power, scan speed, and other parameters to improve print quality and minimize defects.
 
Full Process Chain Simulation

Predict part distortion and residual stresses through every manufacturing stage - from build to final HIP.		  

Accelerated Certification

Reduce physical testing cycles and achieve faster time-to-market with simulation-led validation.

 

By the end of this session, you’ll walk away with a deeper understanding of how simulation-driven insights can reshape your additive manufacturing outcomes.

Expected outcomes

  • Understand how Simufact Additive’s PDA module predicts and prevents key fusion defects in L-PBF.
  • Learn techniques to optimize laser power, scan speed, and process parameters for superior print quality.
  • Explore how to simulate the full process chain - from printing to heat treatment and post-processing - for distortion-free results.
  • Discover methods to reduce physical testing and accelerate certification through simulation-led validation.
  • See real-world examples of how virtual defect prediction enables cost reduction and faster time-to-market.
  • Understand how collaboration with Raytheon Technologies Research Center (RTRC) brings next-level accuracy and industry validation.


Who will find this valuable

Additive manufacturing shouldn’t be a guessing game.

This session ideal for Additive Manufacturing engineers, simulation experts, process engineers, and innovation leads seeking to accelerate their AM workflows across:
 

Aerospace and
Defence		 Automotive and Manufacturing Engineering Services and R&D organizations

See how Simufact Additive’s PDA module, developed in collaboration with Raytheon Technologies Research Center (RTRC), enables you to predict, visualize, and eliminate defects before the first layer is printed; unlocking smarter, more reliable AM production.  

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Take the next step in simulation-driven additive manufacturing.

Be part of a global community advancing precision, performance, and reliability in metal 3D printing. Watch the session focused on advancing metal additive manufacturing with simulation-driven defect prediction and process optimisation to learn how virtual insight translates into real-world results - turning additive challenges into opportunities for innovation and excellence.