Additive Manufacturing, Laser Welding Process Modeling Added to FLOW-3D Products

Flow Science announced the release of its FLOW-3D 2025R1 suite of simulation software, which now includes FLOW-3D AM and FLOW-
3D WELD. This release aldo includes several additions to FLOW-3D CFD simulation capabilities, including discrete element method (DEM) modeling in several modules.

“With the integration of FLOW-3D AM and FLOW-3D WELD into the FLOW-3D product family, we’re putting advanced manufacturing simulation tools into the hands of practicing engineers,” said Flow Science President John Wendelbo. “These are highly accessible but also extremely accurate solutions. And with scalability and automation capabilities, you have something truly state-of-the-art.”

FLOW-3D AM 2025R1 is an additive manufacturing simulation technology for accelerated material and technology commercialization. It includes a fully-integrated simulation platform for laser-based additive manufacturing processes such as powder bed fusion and directed energy deposition, enabling engineers to deliver cutting-edge manufactured products to the market, the company says. FLOW-3D AM introduces a new, unified user interface and pre-loaded process templates that simplify complex simulation setup. Users can easily move between steps in their process simulations while maintaining complete project continuity.

Harnessing the capabilities of the core FLOW-3D solver, FLOW-3D AM 2025R1 now offers support for high performance computing (HPC) platforms, accelerating simulating throughput. Additive manufacturing simulations on HPC platforms are now up to ~9x faster as compared to standard workstation configurations, the company says.

FLOW-3D WELD 2025R1 provides precision welding simulation. This release introduces improved workflows with a unified user interface, simulation templates, new process automation and analysis capabilities, and significant performance improvements, the company says. FLOW-3D WELD’s brand-new user interface allows users to enable all the relevant physics models within a single application as well as define all required material properties for single or dissimilar metal welding applications. A new pre-loaded laser welding template makes simulation setup easier. HPC compatibility increases simulation speeds to laser welding simulations, while a dedicated FLOW-3D (x) node means faster time-to-market by enabling users to streamline model validation, identify process windows, conduct parameter studies, and optimize laser inputs and beam characteristics quickly and efficiently.

FLOW-3D 2025R1 enhances particle modeling with the new discrete element method (DEM) model. This release extends particle-particle interaction capabilities for use cases such as granular material handling, slurry mixing, and particle-laden flows. HPC support reduces simulation runtimes, enabling rapid product development and process optimization.

FLOW-3D CAST 2025R1 helps casting engineers to manufacture complex non-ferrous castings. This release includes improvements to the solidification and shrinkage, shot sleeve, and valve models. An improved solidification and shrinkage model with revised porosity outputs in the new EXODUS format allows users to simplify the analysis and interpretation of porosity.

FLOW-3D HYDRO 2025R1 introduces a new DEM model as well. This model allows users to account for particle-particle interactions such as collision and friction, providing utility beyond that of the standard Lagrangian particle model. The new DEM model provides insights into the stability of rocks or rip-rap in different flow conditions, opening possibilities for cost savings and risk reduction for unique protection systems on riverbanks and other structures. The model can also help users gain insights into grit separation systems, stormwater separators, and other granular flow scenarios where small objects interact with each other.