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Streamlining Metal 3D Printing with ANSYS Additive Solutions

As the benefits of additive manufacturing become increasingly apparent, organizations are seeking ways to improve processes for 3D printing. PADT has long been at the forefront of both Additive Manufacturing and simulation, purchasing our first 3D printer almost 25 years ago, and when the new ANSYS Additive Suite became available, we jumped at the opportunity to combine these two disciplines to improve our yield and part accuracy for parts made with our metal powder bed fusion system.

In this webinar, we will provide a brief update on what ANSYS tools are available for supporting the design and manufacture of additively manufactured parts, along with our experience using said tools, including lessons learned and advice for others who wish to use simulation to drive design and product to take advantage of Metal 3D Printing.
Recorded Nov 28 2018 58 mins
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Presented by
Eric Miller, Co-Owner & Principal, PADT, Inc.
Presentation preview: Streamlining Metal 3D Printing with ANSYS Additive Solutions

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  • Optical System Design & Disruption in Ansys SPEOS 2020 R2 Nov 4 2020 6:00 pm UTC 60 mins
    Robert McCathren, Application Engineer, PADT, Inc.
    When customers evaluate products, the overall look and details can make all the difference. Ansys physics-based imaging, photonics and illumination software streamlines the design process, so you can better understand how your product will look and operate under real-world lighting and usage conditions. Whether you are designing a TV screen, street lighting network, smart headlight, head-up display or interior mood lighting in an automobile, Ansys optical simulation software helps you make your design more efficient and appealing.

    Optical sensors are the eyes of any intelligent system, and Ansys physics-based simulations can help you assess raw signals from camera and lidar systems in their operating environments. You can post-process the simulated data to optimize sensor layout on vehicles in dynamic driving conditions.

    Ansys 2020 R2 empowers Ansys SPEOS users to go further than ever before with enhancements that improve the handling of complex sensors, project preview and computation.

    Enhancements include:

    - Highly accurate camera models drastically improve camera simulation experience

    - A new version of the SPEOS Live Preview increases accuracy, enables faster simulation times when using light sources and provides nearly real-time review

    - 4X faster simulation setup thanks to optimized GUI

    Join PADT's Application Engineer Robert McCathren for a first hand look at the capabilities of optical simulation, followed by what's available for SPEOS in the Ansys 2020 R2 update.
  • Design & Digital Engineering Updates in Ansys 2020 R2 Recorded: Oct 21 2020 45 mins
    Robert McCathren, Application Engineer, PADT, Inc.
    The Ansys Discovery suite of tools allows engineers to improve their 3D design capabilities, by increasing productivity, improving product quality, and spurring innovation. Explore ideas, iterate and innovate with unprecedented speed early in your design process with Ansys 3D design software. Delve deeper into design details, refine concepts and perform multiple physics simulations to better account for real-world behaviors.

    In the Ansys 2020 R2, users can explore large design spaces and answer critical design questions early in the product design process without waiting days or weeks for traditional simulation results. Additionally, these tools have been upgraded to support concept modeling and model prep for importing modified CAD geometry, auto-skinning topology optimization results from Ansys Mechanical for automated geometry reconstruction, and so much more.

    Join PADT's Application Engineer Robert McCathren for a look at 3D product design and updates for Ansys Discovery AIM, Live, and SpaceClaim in 2020 R2.
  • LS-DYNA Updates in Ansys 2020 R2 Recorded: Oct 7 2020 63 mins
    Jim Peters, Senior Staff Technologist, PADT
    When it comes to tools that are effective for running explicit simulation, there is nothing more commonly used than Ansys LS-DYNA. This program is capable of simulating the response of materials to short periods of severe loading and has many elements, contact formulations, material models and other controls that can be used to simulate complex models with control over all the details of the problem.

    LS-DYNA has a vast array of capabilities to simulate extreme deformation problems using its explicit solver. Though this, engineers can tackle simulations involving material failure and examine how it progresses through a part or an entire system. Models with large amounts of parts or surfaces interacting with each other can also be easily handled through this tool, as well as the accurate modeling of interactions and load passing between complex behaviors.

    Join PADT's Senior Staff Technologist Jim Peters for an examination of this simulation tool, along with a look at some exciting new features available in Ansys 2020 R2.
  • The Additive Advantage - Combatting COVID-19 - PVAMC Panel Discussion Recorded: Sep 17 2020 52 mins
    Eric Miller, Principle & Co-Owner, PADT, Inc.
    Join PADT and series of panelists for a discussion on additive manufacturing's role in combating COVID-19, and what advancements have been made in regards to this application since the pandemic began.


    - Eric Miller, Principle & Co-owner, PADT


    - Tyler Smith,Associate Director of Strategic Projects, ASU

    - Nicholas Jacobson, Clinical Design Researcher, University of Colorado Anschutz Medical Campus

    - David Yang, Healthcare Solutions Engineer, Stratasys
  • Development of Pharmaceutical Equipment Using 3D Printing - PVAMC Recorded: Sep 17 2020 47 mins
    Steven Kjar, Design Engineer - BioProduction Division, Thermo Fisher Scientific
    Join PADT and Thermo Fisher Scientific's Steven Kjar for a presentation on the use of additive manufacturing in the development process for pharmaceutical equipment.

    Historically additive manufacturing has had a limited role within companies who supply to the biopharmaceutical industry due to the industry’s requirements on materials and practices. Stainless steel components are typically used and switching over to the implementation of plastic-based materials used in additive manufacturing was a major undertaking.

    Not only do the advanced manufacturing process capabilities of Stratasys 3D printers make for a worthy solution, the company also produces a variety of composite materials that can operate within a bioreactor due to their unique characteristics.

    Register now to learn more about this incredibly unique application.

    About Steven Kjar: Steven has attended many colleges and universities while developing skills, including Snow College, Brigham Young University, Utah State University, University of Washington, and Penn State. After a long search for the perfect career, he found his passion in mechanical engineering with a focus on 3D printing. Steven currently working at Thermo Fisher Scientific as a mechanical engineer in R&D. As part of his responsibilities he has been entrusted with the development of an additive manufacturing program for Thermo Fisher in Logan, Utah, and has spent six years building a 3D printing lab that is now capable of producing ISO13485 compliant parts.

    Steven wants to move to the next challenge of producing additively manufactured parts for end use; parts produced to reduce cost, serve a custom purpose, or to make life better for others.
  • Use of additive manufacturing for product development at Otter Products - PVAMC Recorded: Sep 16 2020 61 mins
    Richard Vinson, Principal Engineer, Otter Products
    Join PADT and Richard Vinson from Otter Products for a presentation on the benefits the company saw when implementing additive into their design process.

    Founded in 1998, Otter Products has grown to become a global innovator of premium protective products for smartphones and tablets. The company's mission, ‘We Grow to Give,’ is executed through popular OtterBox, LifeProof, Liviri and OtterCares brands. Otter Products focus on breaking ground and leading the way to help people do more and go more places with technology in hand.

    With a focus on bringing innovation to it's workflow, the implementation of additive manufacturing was a clear choice for Otter Products. 3D printing has opened up a plethora of opportunities for the company's design process, drastically speeding up prototyping and providing a multitude of color options that allow for completed prototypes to be build in just 30 minutes.

    Register now to learn more about how Otter Products is revolutionizing their prototying with the help of additive manufacturing.

    About Richard Vinson: During his time at Otter Products, Richard has been involved in a number of significant projects. His role is focused almost entirely on mechanical engineering in product design, as Richard is responsible for products in the OEM group, waterproof series, and many others. The innovative focus of Otter Products' workflow allowed him to work closely with both CAD and additive manufacturing to optimize product design and speed up time-to-market.
  • Twin Builder Updates in Ansys 2020 R2 Recorded: Sep 16 2020 47 mins
    Matt Sutton, Senior Mechanical Engineer, PADT
    When designing a new product or updating an existing one, it is imperative that tests are run to ensure it operates as intended in a given environment. Up until recently, these tests are often expensive and time consuming, due to the need for physical testing in order to ensure the accuracy of environmental conditions. With Ansys Twin Builder, users can create a simulation-based virtual replica of an in-service physical asset — in the form of an integrated multidomain system simulation —which mirrors the life and experience of the asset. Digital twins enable system design and optimization and predictive maintenance, and optimize industrial asset management.

    By implementing Ansys Twin Builder, you can improve top-line revenue, manage bottom-line costs and both gain and retain a competitive advantage.

    Join PADT's Senior Mechanical Engineer, Matt Sutton for a discussion on the advantages of using Ansys to build, validate, and deploy digital twins, and how updates in the 2020 R2 release improve this tool's value.
  • Functional Prototyping Today - PVAMC Panel Discussion Recorded: Sep 15 2020 43 mins
    Eric Miller, Principle & Co-Owner, PADT, Inc.
    Join PADT and a series of panelists for a discussion on the current state of prototyping, and the role that additive manufacturing plays.Learn what hardware and best practices help these companies to thrive.


    - Eric Miller, Principle & Co-owner, PADT


    - Todd Anderson, Product Development Engineer, Bullfrog Spas

    - Eric Hales, Director of Product Development, Bullfrog Spas

    - Chris Buttenob, Design Director, Juggernaut Design

    - Andrew Goodfellow, Director of Engineering, Juggernaut Design
  • 3D Printing in Construction - PVAMC Recorded: Sep 15 2020 59 mins
    Ben Shepard, Lead VDC Engineer, Hensel Phelps
    Join PADT and Ben Shepard from Hensel Phelps for a presentation on the company's use of the Stratsys F120 in the construction industry.

    The success of any construction project is dependent on maintaining a high level of quality and attention to detail from the initial planning process, through the construction of the building. As one of the largest general contractors in the United States, Hensel Phelps clearly illustrates a belief in this practice. Prior to implementing 3D printing into its process, Hensel Phelps, like many other construction firms, relied primarily on computer generated imagery (CGI) and hand-drafted modeling to showcase designs and construction basics early on in the planning phase. This initial modeling process is not only key for initial customer meetings, but is also an integral starting point for the construction process itself.

    When weighing different options, the company was drawn to 3D printing due to its advantages over more traditional building methods. Models often require adjustments and changes as they go through the design process. Thanks to its unparalleled production speed, 3D printing allows for faster turnaround on more iterative projects.

    Register now to learn more about this incredibly unique application for 3D printing.

    About Ben Shepard: As a Lead Virtual Design and Construction Engineer at Hensel Phelps, Ben Shepard applies his 16 years of construction industry experience to focus on 3D animation, graphics, and 3D printing. He is responsible for creating 3D models and visuals that are used for procurement efforts and to support the construction process. Ben is a graduate of Colorado State University with a degree in Interior Design.
  • Managing an Additive Production Line - PVAMC Panel Discussion Recorded: Sep 14 2020 62 mins
    Norman Sutcker, Commercial Leader - Aerospace, Stratasys
    Join PADT and a series of panelists for a discussion on their experiences working with additive manufacturing in a production line setting, including everything from running multiple 3D printers to implementing additive alongside more traditional manufacturing practices.


    - Norman Stucker, Commercial Leader - Aerospace, Stratasys


    - Shuvom Ghose, Go-to-market Engineer, GrabCAD/Stratasys

    - Brent Stucker, Director of Additive Manufacturing, Ansys

    - Richard Lawson, Senior Mechanical Engineer, Lockheed Martin

    - Scott Volk, innovation & Strategy, Keselowski Advanced Manufacturing
  • 3D Printed Injection Molding Inserts - PVAMC Recorded: Sep 14 2020 27 mins
    Cole Brubaker, Research Engineer - Innovation, PING
    Join PADT and PING's Cole Brubaker for a presentation on additive's role in improving the injection molding process on a large scale.

    Since its founding in 1959, the name PING has been synonymous with high-quality golf clubs among professionals and casual players alike. While the game of golf is obviously at the core of what it does, the company also has roots in engineering, dating back to its creator, Karsten Solheim, who worked as an engineer at the General Electric company when he started making putters in his garage in Redwood City, California.

    With this emphasis on the technical side of its manufacturing, the company has been able to stand out among its competitors through a variety of innovative and data-driven practices.PING set out to find new technologies that could be used to further speed up and reduce the costs of its development processes. Additive manufacturing has been used at PING for over 20 years in various capacities, so investigating developments in that field was a logical next step. The company set out to pinpoint specific stages in its process through which implementation would benefit the entire manufacturing organization.

    Register now to learn more about this incredibly unique application and implementation of 3D printing.

    About Cole Brubaker: Cole Brubaker is a research engineer at PING Golf focused on the use of 3D printing and additive manufacturing for rapid prototyping and product development. Cole received his PhD in engineering from Vanderbilt University where his research focused on the design and development of functional material systems for 3D printing applications. At PING, he has helped develop processes to quickly evaluate new designs for injection molded parts using 3D printed tooling and insert.The use of 3D printed injection mold inserts has helped to significantly reduce both the time and cost traditionally associated with prototyping across several design iteration
  • Structural Optimization & Additive Improvements in Ansys 2020 R2 Recorded: Sep 2 2020 41 mins
    Doug Oatis, Lead Mechanical Engineer, PADT, Inc.
    With advancements in manufacturing often comes new tools to help drive optimization of said advancements. One of the best examples of this pairing is Ansys simulation and additive manufacturing. Ansys Additive helps to optimize design for 3D printing, determine any potential stresses or distortions, and predict the microstructure of the part based on thermal history during fabrication.

    Simulation eliminates trial and error and gives you confidence that the part will be successfully built the first time with sound structural properties. It also plays a key role in verifying optimized design, with the inclusion of topology optimization. This provides the ability to specify where supports and loads are located on a volume of material, letting the software find the perfect shape.

    With 2020 R2, Ansys provided a series of key updates to these two tools, spanning a variety of areas including:

    - Optimization Setup
    - Parameter-free morphing
    - Modifying STL's
    - UI Improvements
    - And much more

    Join PADT's Lead Mechanical Engineer Doug Oatis for a deep dive into what you can expect with these new updates and how they can benefit both your additive and simulation workflows.
  • Optimizing Electronics Reliability with Ansys Sherlock Recorded: Aug 19 2020 47 mins
    Josh Stout, Application & Support Engineer | Systems, PADT
    Ansys Sherlock automated design analysis software is the only Reliability Physics/Physics of Failure (PoF)-based electronics design analysis software that provides fast and accurate life predictions for electronic hardware at the component, board and system levels in early design stages. A unique, powerful capability of Sherlock is its revolutionary ability to rapidly convert electronic CAD (ECAD) files into CFD and FEA models with accurate geometries and material properties. Through its powerful parsing engine (capable of importing Gerber, ODB and IPC2581 files, etc.) and embedded libraries containing over 500,000 parts, Sherlock reduces pre-processing time from days to minutes and automates workflows through its integration with Ansys Icepak, Ansys Mechanical and Ansys Workbench.

    With its extensive parts/materials libraries, Sherlock automatically identifies your files and imports your parts list, then builds an FEA model of your circuit board in minutes. It also produces a holistic analysis that is critical to developing reliable electronics products. It enables designers to simulate each environment, failure mechanism and assembly that a product might encounter over its lifespan.

    Join PADT's Systems Application & Support Engineer Josh Stout for an introduction to this powerful tool along with a look at what new features and updates have been added in the Ansys 2020 R2 version.
  • Fluent updates in Ansys 2020 R2 Recorded: Aug 5 2020 58 mins
    Sina Ghods, Senior Simulation Support & Application Engineer, PADT, Inc.
    The industry-leading fluid simulation software Ansys Fluent is capable of predicting fluid flow, heat & mass transfer, chemical reactions and other related phenomena.

    Known for delivering the most accurate solutions in the industry without compromise, Ansys continues to provide cutting-edge advancements with each new release. In 2020 R2 users can learn about updates from pre-processing to new physics models and workflow improvements.

    Join PADT's Senior Simulation Support & Application Engineer Sina Ghods for an in depth discussion on what is new and improved in this version of Ansys Fluent, covering topics such as:

    - Meshing Workflows

    - Battery Modeling

    - Multi-phase & DPM Flow

    - Solver Enhancements

    - And Much More
  • From visualization to simulation: Digital Anatomy Solutions for 3D Printing Recorded: Jul 22 2020 28 mins
    Pam Waterman, 3D Printing & Support Application Engineer, PADT
    The Stratasys J750 Digital Anatomy printer truly brings the look and feel of medical models to life with unrivaled accuracy, realism and functionality. Whether used for surgeon training or to perform testing during device development, its models provide unmatched clinical versatility mimicking both the appearance and response of human tissue.

    Bring medical models to life. The J750 Digital Anatomy Printer takes the J750 capabilities to the next level. Step up to the printer’s digital capabilities to create models with an incredible array of microstructures which not only look, but now feel and function like actual human tissue for true haptic feedback. All of this in a single print operation with minimal to no finishing steps like painting, sanding or assembly.

    Join PADT's 3D Printing & Support Application Engineer Pam Waterman for a discussion on the value of this innovative new technology, including:

    - How it solves challenges facing medical device companies and hospitals

    - More realistic, functional, and anatomically accurate modeling capabilities

    - Quicker design and development, leading to reduced time-to-market

    - And much more
  • Mechanical Updates in Ansys 2020 R2 Recorded: Jul 15 2020 37 mins
    Joe Woodward, Senior Mechanical Engineer & Lead Trainer, PADT, Inc.
    From designers and occasional users looking for quick, easy and accurate results, to experts looking to model complex materials, large assemblies and nonlinear behavior, Ansys has you covered. The intuitive interface of Ansys Mechanical enables engineers of all levels to get answers fast and with confidence. Ansys structural analysis software is used across industries to help engineers optimize their product designs and reduce the costs of physical testing.

    Ansys Mechanical is the flagship mechanical engineering software solution that uses finite element analysis (FEA) for structural analysis.It covers an enormous range of applications and comes complete with everything you need from geometry preparation to optimization and all the steps in between. With Mechanical Enterprise you can model advanced materials, complex environmental loadings and industry-specific requirements in areas such as offshore hydrodynamics and layered composite materials.

    In this webinar, PADT's Senior Mechanical Engineer & Lead Trainer, Joe Woodward will cover a few key components of this tool and what is newly available for them in Ansys 2020 R2. This includes updates for:

    - Mechanical Core

    - Mechanical Graphics/Post Processing

    - Linear Dynamics

    - SMART Fracture
  • Designing Novel Antenna Topology and Optimizing Geometry with ANSYS HFSS Recorded: Jul 1 2020 41 mins
    Michael Griesi, Lead Electromagnetics Engineer, PADT, Inc.
    Ever since NASA began its race to space, U.S. technology companies have searched for solutions to solve a variety of challenges designed to push us further in our exploration of the stars. Whether the purpose is for space travel or for launching satellites that track weather patterns, space innovation is gaining momentum. One of the most critical challenges we are trying to solve is how to optimize communication with moving spacecrafts. Tucson Arizona's FreeFall Aerospace has an answer; developing unique antenna systems for both space and ground use.

    When working to develop this technology, FreeFall ran into a number of roadblocks due to limitations in its engineering software tool-set. The company was able to bypass these hurdles and successfully optimize development thanks to the introduction of Ansys HFSS, a specialized 3D electromagnetic software used for designing and simulating high-frequency electronic products such as antennas, antenna arrays, RF/microwave components, and much more. Because of the speed of this tool and its ability to solve multiple simulation challenges in different domains, FreeFall is able to make design changes more quickly and with better data.

    Join PADT's Lead Electromagnetics Engineer Michael Griesi and President of FreeFall, Doug Stetson for a discussion on Ansys electromagnetics offerings, and how FreeFall is able to take advantage of them for their unique application.
  • Combining Simulation with Additive Manufacturing to Optimize Product Design Recorded: Jun 17 2020 55 mins
    Doug Oatis, Lead Mechanical Engineer, PADT, Inc.
    Advatech Pacific, a Phoenix-based aerospace and defense contractor founded in 1995, works to change the way engineering is conducted for the better by incorporating innovative technologies into its customer’s workflow. Based on the success of previous projects, Advatech is a strong proponent of using high-end simulation software such as ANSYS to identify and evaluate the fine details of massive multi-body mechanical systems, whether through simple static analyses or tightly-coupled multiphysics computations.

    Implementing additive manufacturing as an additional way to improve system design presented opportunities to cut back on tooling costs and reduce lead time for several candidate turbine-engine parts. Doing so would also alleviate the challenge of reproducing complex castings, a problem made increasingly difficult by the fact that many of the original casting providers are no longer in business.

    Join PADT's Lead Mechanical Engineer Doug Oatis, and Advatech Pacific's Engineering Manager Matt Humrick for a discussion on Ansys tools with regards to additive manufacturing & topology optimization, and how Advatech Pacific was able to use them to drastically improve the efficiency of their design and manufacturing process.
  • Fighting COVID-19 With Ansys Simulation Recorded: Jun 3 2020 54 mins
    Eric Miller, Principal & Co-Owner, PADT, Inc. & Marc Horner, Principal Healthcare Engineer, Ansys
    Simulation has been and continues to be a powerful tool for helping to drive innovation in the medical industry. Everything from medical devices, to hospital equipment, and even pharmaceutical and clinical practices can benefit from the introduction of simulation technology. This is true now more than ever, as the we all are facing such turbulent times.

    During the COVID-19 pandemic, Ansys is striving to combat the spread of the coronavirus, by backing the ongoing initiatives of customers and partners working in the medical sphere. In order to support healthcare professionals, policy makers, and communities around the world in this endeavor, Ansys is sharing key insights gained from their own analyse, along with those of partners and other collaborators, regarding how to prevent future spread, and treat those already effected by the virus.

    Join PADT's Co-founder and Principal engineer Eric Miller, along with Marc Horner, Principal Healthcare Engineer at Ansys, for a discussion on what the company is doing to combat the virus, as well as a look at some models that effectively illustrate how the tools are being used.
  • Designing Better Rocket Engines with ANSYS Recorded: May 21 2020 64 mins
    Eric Koder, Ansys Account Manager - PADT & Bill Murray, Director of Design and Analysis - Ursa Major Technologies
    In 2017 Colorado based company Ursa Major Technologies put together an expert team of designers and engineers to realize its vision of providing the microsatellite industry with the best rocket engines in the business. Utilizing Ansys simulation software, additive manufacturing, and modernizing staged combustion, the company successfully designed and built two liquid oxygen and kerosene engines and has a third engine in development.

    With Ansys, Ursa Major Technologies is accomplishing design goals faster
    and more efficiently than ever before. Using Finite Element Analysis
    (FEA), the company can run models with 30-40 unique parts to analyze entire
    turbo pumps in one simulation. Thrust analysis, which the company had
    previously done with 2D models, can now be done all in the Ansys CFX tool
    more cost-effectively.

    Join PADT and Ursa Major Technologies for a brief overview of applications for Ansys in the aerospace industry, followed by an exploration of how they are using these simulation tools to better design and optimize the next generation of rocket engines.
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  • Live at: Nov 28 2018 6:00 pm
  • Presented by: Eric Miller, Co-Owner & Principal, PADT, Inc.
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