Simulation lowers the production cost

© Fraunhofer IPK
Simulated distortion on a turbine blade

With the help of state-of-the-art simulation methods, we support you in economically implementing additive processes such as Directed Energy Deposition (DED) and Laser Powder Bed Fusion (L-PBF). Save yourself expensive experiments and use our technologies to optimize your processes and component geometries. We calculate temperature hotspots, excessive stress or unfavorable component distortion in advance and even help you to completely avoid component distortion with simulation-based distortion compensation. Together with you, we work out special process controls, suggest favorable parameter combinations and thus ensure that the additive construction job works from the very start.

Our services

  • Calculation of all DED processes: laser powder cladding, laser-wire cladding, arc-wire cladding
  • Distortion compensation through geometry change
  • Keeping tolerances and reducing finishing operations
  • Visualization of process parameters
  • Optimization of path planning, pause times and machine parameters
  • Design of the process chain additive structure / post heat treatment

Industrial applications

  • Optimal welding sequences for the repair of turbine blades
  • Distortion compensation on components for the aerospace industry
  • Low-distortion coatings of thin-walled sheet metal parts
  • Thermal management for additive manufacturing of sensitive components


Technical equipment


  • Simufact Welding for finite element analysis
  • Trumpf TruLaserCell 7020 for DED technologies
  • Thermal elements and 3D scans for validation measurements
  • Heat treatment furnace Nabertherm LH 60/13



Selected references

Distortion simulation

Using temperature and stress measurements, we analyze potential component distortion directly in the process and prevent it before it occurs.

Geometric distortion compensation

In this publication we explain how transient numerical simulation can be used to create precise component geometries.