Aibuild, a leading innovator in advanced manufacturing software, introduced the BETA release of its new Finite Element Thermal Simulation. This technology marks a significant milestone for metal DED and large-format additive manufacturing with polymers, promising to replace trial-and-error printing with predictive, simulation-led decision-making.

This development is the result of over a decade of rigorous testing and industry collaboration within Aibuild’s proprietary Ailab. Traditionally, thermal management in LFAM has relied heavily on guesswork, often leading to costly build failures, material waste, and significant production delays. The Finite Element Thermal Simulation directly addresses these persistent issues by providing a robust, physics-based approach to thermal control.

According to co-founders Daghan Cam and Michail Desyllas, “After ten years of hands-on research and collaboration with global manufacturing partners, we’ve consistently seen thermal challenges as a critical barrier to successful WAAM implementation. This release encapsulates our deep industry expertise and reflects our mission to elevate additive manufacturing across all sectors.”

Aibuild’s solution automatically generates a finite element mesh using key input data, such as material properties and environmental conditions. The software visualizes the entire thermal simulation of the print before the first layer is deposited. It then adjusts toolpath parameters, including speed, wait times, and processing variables, to ensure temperatures remain within an optimal range throughout the build.

Seamlessly integrated with Aibuild’s toolpath planning software, the simulation offers easy modifications and real-time optimization. Unlike general-purpose FEA tools, which require users to build simulation models from scratch, Aibuild’s platform is specifically designed for LFAM. This focus ensures faster computational speeds and a significantly more intuitive user experience.

Jack Sandiford, Product Manager at Aibuild, emphasized the engineering-first approach: “Our engineering team, in collaboration with our extensive partner network, has developed a solution that redefines thermal simulation in WAAM. This is software designed by engineers, for engineers.”

This innovation positions Aibuild at the forefront of intelligent manufacturing, where decisions are driven by predictive physics rather than manual trial and error. The company is currently rolling out the BETA version in collaboration with select manufacturers in both metal and polymer LFAM. General availability is expected by the end of Q3 2025