AMSIG Tech Session – May 1,2024 How Thermal and Mechanical Simulation Technology is Reshaping the AM Landscape with AlphaSTAR Technology

By Hani Qaqish

In a recent Siemens AMSIG session, AlphaSTAR unveiled groundbreaking insights into the future of additive manufacturing (AM). This article delves into the transformative potential of their collaborative effort, shedding light on essential metrics driving the industry’s evolution.

Arshi Sagati, from AlphaSTAR, commenced the session by outlining the opportunities within the polymer AM market. With a shift towards 3D printing technology, the emphasis on high-value production parts is palpable. The promise of lighter, cheaper, and stronger components is driving this migration, underlining the need for robust solutions.

One key metric highlighted was the challenge of developing materials tailored for AM applications. Arshi emphasized the significance of fine-tuning material formulations to optimize performance, a vital aspect in ensuring the success of AM endeavors.

Another crucial metric is the iterative changes to print parameters. Arshi elaborated on how understanding the effects of these parameters through digital simulation expedites development cycles, significantly reducing costs and time.

Temperature management emerged as a critical factor in AM, with optimal gradients crucial for preventing distortions and residual stresses. AlphaSTAR’s solution offers virtual build analysis to predict temperature changes accurately, empowering users to minimize stress and enhance overall part quality.

The digital revolution’s impact on AM cannot be overstated. Arshi underscored the importance of reliable predictive modeling in driving informed decision-making and increasing confidence in hardware systems.

The heart of AlphaSTAR’s offering lies in thermal-mechanical simulation, enabling users to assess build quality and performance comprehensively. By considering toolpath and print parameters as direct inputs, their solution streamlines the optimization process, reducing trial and error approaches and ensuring parts meet design requirements.

Partner and customer use cases showcased the practical applications of AlphaSTAR’s technology, from stress tests to distortion analysis. These examples underscored the solution’s ability to predict part behavior accurately, providing valuable insights before the actual print.

Arshi’s conclusion highlighted a user-friendly workflow integrated into the NXM center platform. This holistic approach, coupled with predictive modeling, empowers users to make informed decisions, from material selection to part qualification.

In subsequent discussions led by Mallikharjun Marrey, a deeper dive into the solution’s workflow unveiled the intricate process from CAD geometry to material data integration. The seamless integration of machine process parameters ensures a comprehensive simulation experience.

Through AlphaSTAR’s innovative approach, the AM landscape is poised for a revolution. With a keen focus on key metrics like material development, print parameter optimization, and predictive modeling, the future of additive manufacturing looks promising, driven by unprecedented efficiency and reliability.

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This article first appeared on the Siemens Digital Industries Software blog at