Researchers use numerical simulation to predict AM issues
Work from the NRC Canada allows solutions to be developed before production begins
According to National Research Council (NRC) Canada, at the Automotive and Surface Transportation Research Centre, researchers are using advanced numerical simulation to detect potential manufacturing issues early, allowing solutions to be developed before production begins.
Additive manufacturing enables the creation of strong, lightweight parts with complex geometries that traditional methods can’t achieve. While AM has the potential to cut costs and environmental impact, its widespread adoption still faces hurdles—particularly the need to eliminate trial-and-error, produce cost-effective parts on demand or at scale, and reduce time to market. Numerical simulation addresses these challenges by enabling manufacturers to test designs and processes virtually.
The NRC’s simulation team has focused on improving laser powder bed fusion (LPBF), which works by melting thin layers of metal powder with a laser, but build failures and design tolerance issues remain common. “To solve these problems, we’ve developed a fast and accurate numerical simulation method for LPBF that predicts where flaws might occur,” says Dr. Yohann Vautrin. “Our advanced simulation software can predict how metal parts behave during and after printing.” This allows companies to adjust designs or printing parameters before production, saving time and resources. NRC partners in the METALTec industrial R&D group gain access to confidential R&D findings and tailored research support.
The project was developed collaboratively with Polytechnique Montréal, Concordia University, and McGill University, combining expertise across time and length scales. A multiscale simulation approach was created—starting with a high-accuracy microscale model (≈100 µm), followed by a mesoscale model (≈1 mm), and ending with a part-scale model that simulates full-part printing in minutes.
Funded by $1.14 million from METALTec members, CRITM, and NRC’s Advanced Manufacturing Cluster Support Program, the project also trained over eight highly qualified personnel. As the NRC advances simulation tools and collaborates with industry and academia, it supports the adoption of metal AM in Canada—helping to shape the future of transportation through innovation.
