Chaining of Simulations for Metal Additive Manufacturing

Introduction

NAFEMS wishes to commission an author to produce a practical guidance document on chaining simulations (linking simulations of consecutive manufacturing operations) for metal Additive Manufacturing (AM).

In metal AM simulation workflows, engineers increasingly need to transfer results from one simulation stage to the next (e.g., build → heat treatment, hot isostatic pressing or stress relief → machining → inspection → in-service performance). While this “simulation chain” can unlock major predictive capability, it is often limited by how fields and internal state variables are transferred across stages, especially when remeshing or switching models.

This guidance will help engineers make informed, feasible choices about what to transfer, how to transfer it, and what accuracy or effort trade-offs are acceptable.

Intended Readership

Simulation, design and manufacturing engineers working with metal AM process with prior experience in at least one relevant domain (thermal, mechanical, metallurgical, or manufacturing simulation).

Contents

Proposals are encouraged to shape the final structure, but the document is expected to address topics such as:

• Types of simulation techniques, material models frequently used at the different stages of the simulation of metal AM components focusing both on the manufacturing process and design,
• Applications, where the linkage of consecutive simulations is essential in metal AM,
• The fields, state variables and more generally physical quantities that must be mapped in which stages of the chain, to preserve the physical basis of the entire chain,
• Strategies for transferring the complete set of required fields and internal state variables to initialise a subsequent physics-based simulation,
• Mapping data from a source mesh to a different destination mesh while conserving key physical quantities and minimising interpolation error,
• Process automation and optimisation to create a seamless and computationally efficient simulation workflow,
• Best practice examples of this technology.

The work will be carried out in collaboration with the NAFEMS Metal Additive Manufacturing Focus Team. The Group’s knowledge and experience shall be captured through interviews and supplemented by a review of the open literature.

Format

The document should conform to the standard NAFEMS publication template (provided upon contract award).

The anticipated length of the publication is between 50-70 A5 pages.

Cost

The total cost is not expected to exceed £6000 (GBP), and it is expected that the document will be completed within 12 months from NAFEMS approval.

Guidance for Proposals

Each proposal should consist of:

• the proposed structure of the document with the titles of the sections to be developed,
• work plan including milestones and interim deliveries for early review,
• cost.
• The author’s credentials, curriculum vitae, etc.
• list of PSE Competencies that the work plans to address. Contact technical@nafems.org to obtain access.
• A list of new competencies that the publication is anticipated to address.

Submission

All proposals should be sent to NAFEMS at technical@nafems.org to arrive no later than 31st of January 2027.