Category: Blog

Rail vehicle dynamics is the study of the forces and motions that affect trains and other rail vehicles as they travel along tracks. It plays a crucial role in ensuring the safety, stability, and efficiency of rail systems. Whether it’s for passenger trains, freight trains, or high-speed rail, understanding rail vehicle dynamics is essential for designing and operating trains that perform well under varying conditions.

Multi-Body Simulation (MBS) has become a powerful method for studying and analysing rail vehicle dynamics. This approach has significantly transformed the way engineers design, optimize, and test rail vehicles, offering deep insights into their behaviour under real-world conditions. It allows engineers to create a virtual prototype, facilitating virtual testing early in the development process. This approach enables an extensive exploration of the design space, considering multiple key performance indicators (KPIs), to quickly and cost-effectively identify the optimal design among competing alternatives, all while reducing the need for physical testing.

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Rail Wheel Interaction and Its Effects on Vehicle Performance

The interaction between rail wheels and rails is fundamental to the performance, safety, and efficiency of rail vehicles. This interaction dictates how forces are transferred between the wheels of the train and the track, and it impacts a wide range of factors, including ride quality, vehicle stability, track maintenance, energy efficiency, and safety.

Major Impacts of Rail Wheel Interaction:

• Safety: Proper wheel-rail interaction ensures stability and reduces the risk of derailment and accidents
• Ride Quality: A smooth, stable interaction minimizes vibrations, noise, and discomfort for passengers.
• Efficiency: Minimizing wheel-rail wear and rolling resistance helps improve energy efficiency and reduce operating costs.
• Maintenance: Understanding wheel-rail interaction helps in reducing wear and tear on both vehicles and track, lowering long-term maintenance costs.

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Optimizing Rail Vehicle Performance through Multi-Body Simulation Capabilities

• Ensuring Safety, Reliability, and Comfort: Simulation tools enable the analysis of rail vehicle dynamics to ensure safe, reliable, and comfortable transportation for passengers.
• Reducing Development Costs: By leveraging simulation, costly physical testing can be minimized, allowing for more efficient development processes and reducing overall project costs.
• Designing Environmentally Friendly Solutions: Simulations help in developing rail vehicles with energy efficiency and reduced environmental impact, supporting sustainable transport solutions.
• Innovating for Competitive Advantage: Using advanced simulations fosters innovation, allowing manufacturers to design vehicles that outperform competitors in key areas such as performance, comfort, and sustainability.
• One Model for multiple analysis: A single rail vehicle model supports a variety of analyses, including critical speed analysis, derailment simulations, Roll coefficient, comfort analysis, rail wheel wear, flexible track modelling, and gauging analysis, making it an all-in-one solution for comprehensive vehicle performance studies.
• High-Fidelity Element Modelling: The ability to model complex systems such as air suspensions with gas equations allows for detailed and accurate simulations of vehicle behaviour under varying conditions.
• Advanced Rail-Wheel Contact Algorithms: Simpack features sophisticated algorithms to precisely calculate the forces between wheels and rails, improving the accuracy of simulations for dynamic vehicle performance.
• Design of Experiments (DOE) Studies: Incorporating DOE allows for systematic testing of design variables, enabling engineers to optimize vehicle components and performance through data-driven decision-making.

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Simpack – MBS Application for All Types of Rail System 

Multibody system simulation (MBS) is a powerful tool for analysing and designing a wide range of rail-based or guided vehicles and mechanisms, including everything from tram cars to fully articulated high-speed trains. It is also applicable to specialized systems like roller coasters, material handling equipment, and even maglev trains. Simpack, the leading MBS software for railway system dynamics, is widely utilized by manufacturers and operators around the globe.

Typical applications include:

• Critical speed calculations
• Derailment safety
• Passenger comfort
• Curving and on-track simulations
• Profile and track optimization, wear and rail-contact-fatigue
• Gauging
• Switches and crossings
• Suspension modelling

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Analysis of Wheel and Rail Wear

The rail industry faces significant challenges in managing the wear and tear of its infrastructure, with maintenance costs accounting for over 50% of total expenditure on railway operations and infrastructure in the EU alone, amounting to over 20 billion euros annually (Seventh Rail Market Monitoring Report, European Commission). To address these issues, simulation tools like Simpack—a powerful Multibody Simulation (MBS) software—are increasingly being used for simulation-aided maintenance. This approach not only helps optimize the design of rail vehicles but also offers significant cost-saving opportunities throughout the lifecycle of the rail system. 

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Understanding the Impact of Wheel and Rail Wear 

Wear between the wheels of rail vehicles and the tracks is an inevitable phenomenon driven by several factors, including friction, contact forces, and operational conditions. As this wear progresses, it leads to the deterioration of both wheel and rail profiles, contributing to safety concerns, increased maintenance costs, and potential operational disruptions.

Wheels and rails are particularly susceptible to Rolling Contact Fatigue (RCF), a form of wear that can cause cracks and material degradation, leading to significant repair needs. Managing these issues is vital for the safe and cost-effective operation of railway systems, and this is where Simpack plays a critical role. 

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Flexible Track Simulation 

The dynamic behaviour of a rail vehicle can be significantly influenced by the flexibility of the track and its supporting structure. With track systems such as ballasted tracks or diverging crossings with flexible blade rails, the relationship between the vehicle and the track is not one-sided; the vehicle dynamically responds to the track, while the track also reacts to the vehicle’s movements. Including the track’s flexibility in simulations allows for a comprehensive analysis of the coupled dynamic responses of both the rail vehicle and the track due to their material flexibility. This interaction can range from observing the deflection of a switch blade rail as a vehicle passes over it to assessing the vibrations throughout an entire bridge. Additionally, the loads acting on specific track sections can be extracted and used for further analysis in finite element software or specialized tools for fatigue and durability studies. 

Simpack technology facilitates the modelling of flexible track sections based on finite element principles, enabling in-depth investigation of advanced train/track interactions. Multiple flexible track segments can be modelled simultaneously, making it possible to analyse the dynamic behaviour of various track structures comprehensively. Simpack offers two modelling options to cover different levels of fidelity. The standard method models linear deformation, providing a fast calculation workflow that is accurate enough for large and complex systems like bridges. The higher-fidelity approach captures more detailed aspects of track behaviour, including the compliance of the track and ballast, and accounts for geometric nonlinearities, such as the coupling between the vertical and lateral flexibility of the track. 

Flexible track simulation plays a vital role in the dynamic analysis of various components, including: 

• Sleeper foundations 
• Rail joints 
• Rail pads 
• Hanging sleepers 
• Coupled effects of leading and trailing wheelsets 
• Loads within the track structure 
• Switches and crossings 
• Bridges

 

By simulating flexible track behaviour, Simpack enables a more detailed understanding of how track and vehicle dynamics interact, ultimately helping to optimize track design and improve the overall safety and performance of rail systems. 

Understanding Post-Flight Review and Visualization  

Post-flight visualizers (also known as flight data emulators, flight data analysis, or flight replay systems) are essential tools in modern aviation training, designed to analyse and replay real-world flight data within a controlled simulation environment. These simulators enable pilots and instructors to scrutinize flight dynamics, decision-making processes, and overall performance. By recreating flight scenarios, they offer a comprehensive understanding of both routine operations and critical incidents, providing insights that are crucial for continuous improvement in pilot training and safety. 

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Challenges in Implementing Post-Flight Visualization 

Despite their significant benefits, implementing post-flight simulators comes with inherent challenges. Basic 2D simulators, while effective for initial data analysis, often lack the depth required for understanding complex manoeuvres and spatial relationships. Transitioning to 3D simulation environments introduces a higher level of detail and realism but demands more sophisticated hardware, software, and user training. Furthermore, high-fidelity 3D simulators, which offer the most realistic and detailed recreations, require substantial computational power and specialized equipment, making them less accessible for smaller training programs.

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2D vs 3D Post-Flight Visualization  

2D post-flight simulators provide a straightforward, two-dimensional view of flight data, focusing on key elements such as flight paths, altitude changes, and control inputs. These are highly effective for quick debriefs and basic flight analysis. 

On the other hand, 3D post-flight simulators offer a more immersive experience by recreating the flight in a three-dimensional space. This level of simulation allows for a more accurate representation of flight dynamics and spatial relationships, making them ideal for advanced training scenarios that require a deeper understanding of flight mechanics and situational awareness. While transitioning to 3D simulators may require greater technological investment and resources, the benefits of a richer, more detailed training environment are undeniable. 

_{Top Left: Ownship view for pilot | Top Mid: Stealth view for IOS | Top Right: Cockpit view 
Bottom Left: Exaggerated view for scenario overview | Bottom Mid: Sensor view | Bottom Right: 2D view in MAK’s VR Vantage}  

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Proposed Tiered Approach  

Recognizing the diverse needs of aviation training programs, our approach offers a tiered solution for post-flight simulation. We provide a range of simulators: 2D visualization for basic analysis, generic 3D visualization for enhanced spatial visualization, and advanced, high-fidelity 3D simulators for the most detailed and realistic training experiences. This approach allows training programs to choose the level of simulation that best aligns with their objectives, resources, and training requirements, ensuring both flexibility and scalability. 

 

_{Scenario development for enhanced visualization in MAK’s VR Forces} 

 

_{Multiple panels representation for enhanced analysis and control}

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Conclusion  

Post-flight simulators are indispensable in the field of aviation training, offering detailed insights that are crucial for refining pilot skills and enhancing safety protocols. By selecting the appropriate level of simulation—whether it be 2D for basic analysis or high-fidelity 3D for advanced training—aviation programs can effectively tailor their training environments to meet specific needs. Our tiered approach ensures that all training programs, regardless of size or complexity, can access the tools necessary to elevate their training outcomes and prepare pilots for the demands of real-world flight operations. 

Customer expectations are growing with the need for lower costs, higher quality, increased capabilities and the ever-growing complexity making it even more challenging for manufacturers. Complex system requirements challenges OEMs and suppliers to amplify their creativity, collaboration and innovation by upgrading to the factory of the future focused on improved efficiency and production agility. New approaches towards conception, designing, manufacturing, validation and sustenance are required for new air, space and defense vehicles.

Aerospace & Defense companies face a spectrum of challenges as well as growth opportunities with the continued growth of commercial aviation and an increase in the defense budget. With the increasing number of projects, there is an increase in Request for Proposals’ (RFPs) but manufacturers have less time to respond to complex RFPs for multiple components in a competitive environment for better customer experience.

Dassault Systèmes provides a portfolio of industry-specific solutions through the 3DEXPERIENCE platform for Aerospace & Defense manufacturers and suppliers to transform the traditional process with new and latest technologies.

Powered by Dassault Systèmes’ 3DEXPERIENCE platform, EDS Technologies provides industry solution experiences to transform your business processes with enhanced efficiency and digital continuity:

• Engineered to Fly accelerates A&D supplier process from idea to delivery with enhanced margins
• Co-Design to Target delivers aerospace programs ‘On specification’, ‘On- time’ and ‘On-Budget’

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These solutions enable

• Driven & Controlled Execution: Displays the status of current proposals and KPIs regarding costs and risks to enable process visibility. Project execution is driven in a connected process. The intellectual property is secured with traceability for authorities to manage collaborative efforts with multiple customers in a single source environment to ensure OEM certifications.
• Operational Efficiency: Predefined proposal templates, automated routing and tracking, clear view of projects to implement, accessibility to design and manufacturing components and collaboration with OEMs help streamline the whole process.
• Digital Continuity: From design engineering to manufacturing, best in class engineering tools are in place with quality and efficiency in a controlled environment to maintain digital continuity.

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Engineered to Fly

Engineered to Fly is tailored to the aerospace industry with essential features and functionalities. It includes robust tools to help A&D businesses ‘Built-to-print’ or ‘Design-and-build’ to manage their whole business process. Some of the capabilities include addressing RFPs promptly, executing the projects with APQP and quickly adapting new changes in the current manufacturing process.

Project execution is driven and controlled with real-time status tracking throughout the stages of a proposal to product delivery. Validation and quality assurance are integrated for certification to meet the OEM standards. The value chain maintains digital continuity to deliver products with enhanced process efficiency and business profitability.

For instance, an aircraft’s frame is composed of sheet metal parts comprising 4,700 rivets. With engineered to fly, the sheet metal is designed in 3D to position the rivet holes so the part assembly process is error-free and done right the first time. Also, each part is versioned and tracked for easy access to real-time product data as required to relevant stakeholders through digital continuity.

Digital continuity enables improvements in the holistic process for up to:

• 30% error reduction
• 40% productivity boost
• 40% process changes requested

 

Benefits

• Win more business: Significant cut down of the proposal response and turnaround time has helped in the business growth with improved bid quality for up to 25% without additional stakeholders.
• Stay in control: Execution across multiple organizations through real-time KPIs with full traceability for stakeholders or OEM certifications.
• Drive design & production efficiency: Digital continuity across all value streams from engineering to manufacturing to eliminate inefficiencies in the design process and ensure product quality.
• Higher margins: 40% increased productivity with 30% reduce in change process requests and errors with strong controls, rules-based optimization and seamless collaboration

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Co-Design to Target

Over 50% of projects miss out on their delivery data due to issues in the later stages that are discovered in the manufacturing process. Designing right the first time can prevent these issues in the first stage with the automated validation and quality assurance against the OEM standards.

Co-Design to Target enables OEMs with disparate tools and processes in a single stream to optimize the form, fit and function within an integrated Digital Mock-Up system (DMU). This system eliminates many integration issues that majorly affect  cost and schedule.

Digital Continuity allows driving projects with a real-time view of KPIs across the organization with multiple stakeholders, sites and suppliers to proactively sustain the project as per the timeline.

For instance, hundreds of engineers work on  detailed product development in the design phase. Thousands of specifications cascade to sub-systems and components based on top-level requirements. Project targets are met with lean development through efficient integration of engineering teams. With Co-Design to Target, these teams work with parallel timelines and collaborate in real-time for quick and easy detailed definitions of each component and system within the finished product.

 

Benefits

• Manage programs in real-time: Stakeholders can review the real-time status of projects with a quick view of all KPIs with full traceability until delivery. The works-in process is consolidated with various different tools for program controls, systems engineering, design engineering, contracts management, subcontract administrations, configuration management, and data management. Comprehensive management and real-time process visibility improve the success, profitability and value to customers.
• Achieve manufacturing excellence by design: Design, engineering and manufacturing processes are efficiently integrated and validated with the digital mock-up function to evade costly issues in the later stages. This solution simplifies the product development process by integrating value streams. Transformation in the development phase significantly lowers the cost and time of projects with Co-Design to Target.
• Reduce costs and improve quality: Program execution is enhanced with multi-discipline simulations to guarantee the delivery of performance, reliability and cost targets. Reducing the complexity in product development stage enables organizations to reap the profits at a lower recurring and non-recurring costs. Co-Design to Target industry-specific solution transforms the product development phase to ensure significant reduction in cost with improved quality.

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To know more about our aerospace & defense industry-specific solutions,submit an inquiry to speak to our senior technical experts.

Data is the backbone of the mining industry. Every mine must have reliable, up-to-date information to make the best possible decisions, from first dig to end of life. 

Historically, mining data has been confined to departmental silos, limiting its utility for mining organizations at large. Mining data helps gain an understanding of the “what” in data. Mining Intelligence answers the “how” and “why” to provide a comprehensive view of data. Together they enable mining companies to perform, test, and interpret sophisticated analyses quickly. 

Miners can at once respond to worldwide and mine-specific challenges with evidence-based decisions, cutting through silos and interlinking various departments. This enables enhanced collaboration and knowledge sharing, while ensuring knowledge is retained across the organization even during multiple staff changes. 

In the current scenario, more and more technological advancements are made in data collection. It is easy to become overwhelmed by the sheer volume of new, incredibly detailed information arriving every day. And to be confused about exactly how you are going to collect, store, and analyze it all. The reality is that not every mine has the expertise and experience it needs to complete a complex data analytics project. Yet in the current mining environment, it is becoming increasingly vital that mines use all the data at their disposal in order not just to maintain the status quo, but to get ahead in a competitive industry. 

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Need for Data Intelligence in Mining Industry 

Data intelligence plays a crucial role in the mining industry for enhanced decision-making, optimizing operations, and improving safety and sustainability. Data converted into valuable information is particularly useful in key areas such as predictive maintenance, resource estimation & optimization, risk assessment, incident analysis, waste management, environmental impact monitoring, inventory management, logistics & transportation, exploration, transparency & reporting.  

Embracing data intelligence in the mining industry not only drives efficiency and profitability but also fosters a safer and more sustainable approach to resource extraction. As technology continues to evolve, the potential for leveraging right data and information will only increase. 

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Big Data – A Fact of Life for Mining Companies 

Mines must gather a vast amount of information and verify it against economic calculations and regulatory compliance. During mine design and planning, engineers must add information about how the site will be rehabilitated and relinquished. Later, once the mine is in operation, mine-to-mill optimisation demands up-to-date data from every stage of the process – such as data on the effectiveness of blast design, or on recovery rate, co-product valorisation, water recirculation, waste dewatering, etc. at the processing plant to make each stage more productive and therefore more profitable. At the same time other data such as data related to the effect of fleet powering choices (fossil fuel, natural gas or electricity) on the mine’s carbon footprint, is required to ensure sustainability.  

A lot of mining data today is what is known as “big data.” Potentially many terabytes in size, most big data is “soft”, or unstructured (qualitative) data as opposed to “hard” or structured (quantitative) data. 

Hard data is directly observed and measured and easily put into searchable rows and columns. Soft data includes text, video, photographs, scans, etc., as well as metadata – in other words, data without structure that cannot be put into rows and columns. To understand and take advantage of all your data, your soft data must be able to work with and be stored, viewed, and analysed alongside – your traditional hard data, such as the lithologies, assays, and other physical drilling information used in resource estimations.  

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Why Virtual Twin Experiences are Key to Mining Intelligence 

Modern mining operations are intricate systems of systems, surpassing the capabilities of industry solutions to analyze them. To fully harness the potential of big data, it’s important to identify the different systems generating it, understand their functions, and delineate their boundaries and interconnections. This enables effective management of data flow between these systems. 

This level of interconnected data management is achievable through virtual twin experiences. Unlike standard digital twins, virtual twin experiences offer a dynamic, live virtual representation of the real world. 

The applications linked to this system of systems incorporate smart algorithms that empower AI techniques to suggest decision options based on past data, current behaviour, and possible simulated outcomes based on those decision options. 

Having a digital continuity between financial assumptions based on commodity prices, energy cost and so on as well as geology, terrain, and in-field operational information enables mining companies to achieve consistency in planning from short-term to long-term and vice-versa. This also helps avoid having contradicting decisions implemented at the same time in different parts of the mine, which can hurt Net Present Value. 

The virtual twin enables three levels of data analytics:  

• Descriptive:   Examining what happened
• Predictive: Examining possible outcomes based on what happened 
• Prescriptive: Prescribing roadmaps based on possible decision options to adjust to various evolving factors on the go, thereby permanently pursuing value in all operations 

This approach minimizes waste and risk and maximizes productivity by reducing unnecessary material re-handling. 

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How can Mining Industries turn Data into Valuable Business Insights 

Turning data into valuable business insights through data analytics involves several key steps. Here’s a structured approach that is required for business transformation:  

• Identify your issues 

• Collect, store, and integrate your data 

• Analyze your data/define your dashboards 

• Publish your data 

• Share your data 

 

Once all the data is in a single repository, it can be well organized and integrated using the most appropriate GEOVIA Mining Intelligence applications on the 3DEXPERIENCE platform as detailed below: 

 

Exploration Intelligence  

• Index all geological data, both structured and unstructured, from various source systems  

• Create a visual overview of all exploration data  

• Measure, analyze, display, and share data, and  

• Develop detailed, drilldown views of specific exploration activities, such as drilling sampling results sorted by their campaign code, status and period 

 

Geology Intelligence  

• Index, analyze and report tonnages, grade, volume, material type and other metrics  

• Compare multiple versions of the block model  

• Share results internally with other teams or stakeholders across the mine 

• Display and share specific analytics, such as an analysis of the estimated weight of ore, waste and average grade for various cut-off grades, or a comparison of the mathematical (spherical) model and variogram curve from the drill hole

 

Production Intelligence  

Index production data at source, analyze it and visualize the results using a range of standard dashboards, including dashboards that 

• Monitor production actuals against targets, ore processing metrics and equipment performance  

• Review stockpile balances and equipment fuel consumption 

• Reveal material flow and key performance indicators 

 

Traditionally, mining processes were manual, with strategic planning conducted by engineers across various disciplines using Excel while managing data in silos. The Dassault Systèmes’ 3DEXPERIENCE platform leverages the existing mining engine to introduce a cloud-based data analytics layer on top of it to democratize data. 

The platform integrates and automates mining processes, dismantles silos and enables executives to focus on higher-value areas and optimized geotechnical, economic, productivity and ESG parameters. The optimization ensures positive cash flow or net present value (NPV) while adhering to sustainability and compliance goals. 

Overall, GEOVIA Mining Intelligence on the 3DEXPERIENCE platform represents a leap forward in the quest to gain a competitive edge. 

Its four powerful applications provide efficient and effective methods for: 

• Gathering all your big data into one place 
• Indexing it so it is immediately ready to retrieve and analyze as required, and 
• Understanding it more deeply than you ever thought possible through multiple visualizations, leading to Better-informed decisions and greater productivity.  

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To get more information & insights on how the 3DEXPERIENCE Platform drives business transformation in the mining industry, please reach out to us at marketing@edstechnologies.com   

The rapidly evolving optical industry demands cutting-edge systems with exceptional precision and accuracy. As the market for these advanced solutions grows, engineers and manufacturers must swiftly introduce unique and affordable lighting technologies. With the rise of virtual prototyping and digital twins, the capability to meticulously design, simulate, analyze and optimize light behaviour is paramount. Combining Synopsys’ optical software suite of LightTools, CODE V, LucidShape, and RSoft makes it possible to create a diverse range of optical systems for industries like automotive, aerospace, telecommunications, and healthcare. These powerful tools streamline the development process, reducing reliance on expensive physical prototypes and minimizing risks.   

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Automotive Optical Solutions

Autonomous driving technology (ADS) and advanced driver assistance systems (ADAS) are revolutionizing the automotive industry. These systems require sophisticated lighting solutions, including pixel headlights, high and low beam lamps, tail lights, indicators, and head-up displays, to enhance safety and reduce driver distractions. 

Beyond these external components, dashboard illumination, light guides, and interior lighting are crucial elements of a modern vehicle. To ensure optimal performance, it’s essential not only to design the system and analyze light distribution but also to visualize the system under various lighting conditions and conduct on-road simulations to evaluate its real-world behavior. 

 

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Imaging Lenses Design

The lens design is the foundation of numerous optical systems, including cameras, projection displays, medical instrumentation, space and defence technologies, and microlithographic lenses for imaging intricate patterns on computer chips. Optimizing key features like wavefront variance, modulation transfer function (MTF), and coupling efficiency is preeminent in creating high-performance imaging systems.  

 

Analyzing stray light and simulating ghost images arising from total internal reflections is crucial for understanding potential image degradation. Additionally, factors like lens element weight, cost analysis, system alignment, and interactive tolerancing help assess the impact of manufacturing variations on system performance, ensuring the delivery of an optimal as-built optical system. 

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Medical Instrumentation

By mastering the fabrication of optical and photonic devices, we can pave the way for innovative medical solutions that revolutionize healthcare. Biological sensors are designed to analyze the optical characteristics of biological samples, determine their molecular composition, aid in disease diagnosis, and track drug delivery.  

Metal lens used in endoscopes and optical coherence tomography (OCT) offer advantages such as miniaturization and improved imaging capabilities. Additionally, reflector cups for surgical lights must adhere to stringent illuminance distribution regulations to ensure optimal illumination and patient safety. 

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Silicon Photonic Systems

Semiconductor lasers are fundamental for modern optical communication systems, enabling high-speed data transmission over long distances. Efficient fiber coupling, achieved through carefully designing fibers, couplers, and coupling lenses, is critical for minimizing optical losses. Modulators, including electro-optic, thermo-optic, and carrier modulators, enable the control and manipulation of light signals. 

LiDAR systems, which utilize laser technology for ranging and detection, are gaining prominence in applications like autonomous vehicles and robotics. On-chip LiDAR systems, incorporating components like transmitters, phased arrays, and multi-physics utilities, offer advantages in size and integration. 

Synopsys’ comprehensive suite of optical solutions provides unparalleled capabilities for design, visualization, and simulation. As the demand for advanced optical technologies continues to grow, Synopsys’ solutions are poised to play a vital role in driving future innovations. 

Synopsys’ comprehensive optical solutions suite provides unparalleled design, visualization, and simulation capabilities. As the demand for advanced optical technologies continues to grow, Synopsys’ solutions are poised to play a vital role in driving future innovations. 

Additive Manufacturing (AM)

Additive Manufacturing (AM), commonly referred to as 3D printing is a manufacturing process to form 3D physical parts from CAD DATA. In AM process, hundreds or thousands of layers come together to form the physical 3-dimensional part by means of either binders or direct energy deposited on the material.

Due to very short lead time involved in the development of parts, the AM process used for manufacturing the prototypes rapidly is referred to as Rapid Prototyping. AM has gradually attained its importance in many industries like Aerospace, Healthcare etc. where use cases are proven for series or batch production also. This is only possible through high throughput and productivity of the latest systems that companies like EOS GmBH are manufacturing to yield the best of its productivity and optimized outcome. This brings down the ultimate cost of the parts produced through AM process.

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Benefits of Industrial AM Process

• Tool free technology to develop parts through only Digital Data.
• Short lead time to market.
• High performance materials engineered for different applications.
• High accuracy in first outcome.
• Design Flexibility at any time.
• High Repeatability with systems like EOS.
• Sustainability due to less environmental impact and sustainable material supply chain.
• Material reusability of highly efficient AM processes like SLS and DMLS.
• High strength of the printed materials in AM processes like SLS and DMLS.
• Reduced Physical inventory and practical possibility for JIT in supply chain.

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Workflow of Industrial AM Process

The Industrial AM process typically involves three stages –

• Pre-processing (Designing/ Data Preparation/ Build Simulation/ Build Optimization/ Slicing/ Programming for 3D printer or Parameter Assignment)
• Printing Process and
• Post Processing (Depowdering/ cleaning/ shot blasting/ Heat treatment/ support removal/ post machining etc.)

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Classification of Industrial Additive Manufacturing

Based on the raw material form, energy source used and technology workflow, the AM process is broadly classified into 7 Categories as follows:

• VAT Photopolymerization
• Material Jetting
• Binder Jetting
• Material Extrusion
• Powder Bed Fusion
• Sheet Lamination
• Direct Energy Deposition

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We shall discuss in detail about the above categories and subcategories of the AM processes in coming series.