Hexagon’s Manufacturing Intelligence division has introduced Advanced Compensation, a breakthrough technology designed to eliminate trial-and-error in 3D printing of precision metal components. This innovation helps ensure parts meet exact specifications during production by combining simulation and metrology-based compensation.
Additive manufacturing, particularly in laser powder bed fusion (LPBF), often struggles with dimensional accuracy and surface quality, which are critical for industries like aerospace, medical, and machine building. Hexagon’s Simufact Additive software accurately simulates distortions and shrinkage, reducing the need for print trials. For more complex features, VGSTUDIO MAX software analyzes 3D scans and compensates for local distortions to ensure high precision.
Hexagon’s Advanced Compensation takes this a step further by merging process simulation and 3D scan-based adjustments. This hybrid approach allows manufacturers to print even the most challenging parts — such as thin-walled components or those made of materials like titanium or Inconel — with tolerances as tight as 0.2 mm, often in just one prototype build.
A notable success story comes from Additive Industries, which used Advanced Compensation to produce a stainless-steel jet engine exhaust mixer with 0.2 mm precision on their first try, overcoming a previous deviation of over 3 mm. This method saves time, reduces material waste, and accelerates production cycles.
The workflow integrates seamlessly into Simufact Additive, enabling users to pre-deform parts using simulation and fine-tune them with 3D scan data, without requiring metrology expertise. This makes achieving high-quality 3D-printed parts faster and more accessible.
Advanced Compensation will be available in Simufact Additive’s Q1 2025 release, offering a powerful solution for manufacturers seeking efficiency, precision, and reliability in metal 3D printing.
