Silent animation without text: a wall is built layer by layer, first with wavy layers, then evenly.
Simulation software for laser DED with wire or powder
Simulate. Optimize. Print.
The software adapts laser power, travel speed and material feed layer by layer and writes them into your machine file. Your team checks the file before the print.
In laser DED, a form of metal 3D printing with wire or powder, a laser melts the material and builds the part layer by layer.
How much heat the process must put in depends on the printed geometry and the material used. With a fixed parameter set, the layer height can therefore vary.
Laser DED parameters are still determined in elaborate physical test series, for each material and each geometry. These trial-and-error procedures take considerable time and raise engineering costs up front.
Synafloat develops physics-based simulation software for metal 3D printing. It moves parameter development from the printer into the simulation and computes adjusted parameters for your part before it is printed, to speed up process development.
Because the layer height drifts with a fixed parameter set, the software adjusts the parameter set layer by layer.
The layer height drifts and the build becomes unstable.
Cube demonstrator, fixed parameter setThe layer height stays constant.
Cube demonstrator, adjusted parameter setThe software computes parameters for six applications, from new parts to coating, build-up on existing parts and repair.
Build a wall over many layers while heat accumulates.
Goal: constant layer height over 40 minutes of build time.
Laser power stays between 640 and 1620 W over 40 minutes and decreases as the part heats up. Wire feed stays between 5.8 and 12.6 mm/s and rises because the accumulated heat can melt more wire.
Your team receives the machine file with adjusted process parameters, checks it before the print and uses it for further process development.
Instead of a computational mesh, freely moving particles (SPH) represent the melt. This lets us simulate whole toolpaths, up to whole parts, in one run.
A moving computational mesh has to be adapted to the growing part; the particles follow the material.
In a pilot project we calibrate the simulation to experimental results from your machine. We set the scope per enquiry.
Platform, screenshot
The platform is in development. We are happy to talk about a pilot project for your process, or you can register your interest in platform access.
Platform: in development
You pick the slot on book.synafloat.com.
You talk to Dr. Michael BlankThe founder has researched particle-based melt-pool simulation since 2017 and earned his doctorate in the field.
In a call we clarify whether the simulation answers your parameter question.
Partner: Friedrich-Alexander-Universität Erlangen-Nürnberg (FAU). Synafloat is a spin-off of FAU.
Incubated at the ESA Business Incubation Centre in Bremen since November 2026.
