Identify and address distortion in your support structure

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In Netfabb, you can use process simulation data to identify areas on your support structure that require adjustment.

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Identifying these areas prior to manufacture allows you to eliminate or minimize distortion prior to 3D metal printing,

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creating a more efficient and precise manufacturing process.

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In this example, a part with supports is generated for 3D metal printing,

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and simulation data has already been loaded from Netfabb local simulation.

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In the Browser, Supports_2_mechanical.case is selected to open the visualization.

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The color coding indicates that the part will be heavily distorted when manufactured.

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Blue indicates minimal to no distortion, while green, yellow, orange, and red indicate areas of increasing distortion.

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To link the simulation results with the part, in the context view, click Assign simulation to part.

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In the Assign simulation to part dialog, select the part, then click OK.

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Now, you can drag the simulation results over to view them side-by-side in the machine workspace.

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From the Browser, you can switch among the Generate Support, Machine workspace,

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and Simulation results views to identify the support geometries that require improvement.

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You can also link the mechanical simulation results directly with the support.

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With the simulation selected in the Browser, in the context view, click Display for support editing, and then click OK.

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This visualization can help you to determine how best to optimize the supports. Here, in the context view,

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use the slider bars to adjust the Opacity and the Displacement scale to better view the areas in which the supports bend or are deformed.

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You can also adjust the Displacement Magnitude settings,

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such as Show simulated part and Show simulated supports to enable and disable the simulation results for these features.

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Additionally, there are automated optimization options that are especially effective with bar support.

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For example, you can use a density map to apply a yield stress to all bars, so that they are appropriately adjusted.

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Click Generate density map, set the Yield Stress—in this case, to 1500—and then, click Generate.

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There is also an option to optimize your support lattice.

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Optionally, click Optimization Settings first.

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Adjust the settings to better fit your use case, click Save, and then click Optimize Support Lattice.

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Review the progress of your optimization in the Joblist, and notice that the supports automatically adjust as the optimization runs.

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Additionally, the context view updates with a histogram that displays Bar stress as the supports are enhanced.

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Finally, you can use the manual density map controls to adjust the size and thickness of bars in any local area.

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On the ribbon, click Support > Edit Density Map.

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In the view, use your cursor to resize and move the controls.

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Then, use the Size, Density, Clipping and Alignment tools to edit your supports accordingly.

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When you are finished, click Apply to Part.

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Now, you can easily view simulation results to identify areas of your support structure that require adjustment,

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allowing you to optimize your supports, and minimize or eliminate distortion for an efficient 3D metal printing process.