Inspection of Computed Tomography (CT) Data and Finite Element (FE) Simulation of Additive Manufactured (AM) Components

Abstract

One of the challenges of working with Additive Manufactured (AM) metal parts involves checking accuracy and reliability before production. Techniques used Computed Tomography (CT) scans, 3D image processing, and Finite Element (FE) simulation help detect problems prior to costly faults. A workflow has been developed by Synopsys, ANSYS, North Star Imaging, and the University of Pittsburgh to streamline this often-complex process, with applications to analyzing metal AM-produced lightweight brackets and a component from Moog, Inc. Software like Synopsys Simpleware™ is used to generate robust models from 3D scans of AM parts to compare original CAD models with ‘as-built’ geometries, and to export a FE mesh for simulation in ANSYS. This method enables identification of design deviations early in the design process, and how their impact might be tackled prior to production. For the Moog application, unexpected defects were identified for aerospace parts to inform future design iterations