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AlphaSTAR’s ICME Approach

Integrated Computational Materials Engineering

Multi-scale
Progressive Failure
Analysis

In modern engineering, revolutionary products are dependent on revolutionary material systems.. Whether pursuing hypersonic applications, deep ocean energy extraction, or extremely sensitive medical devices, understanding materials, predicting material behavior, and establishing material databases are the foundation for successful product development.

Material
Characterization &
Qualification

In the realm of Additive Manufacturing, our software tools allow builders to apply predictive analytics in ways that avoid common 3D printing defects, while analyzing the phase change and microstructural change that takes place during the production process — from powder to finished parts.

Build Simulation
for Additive
Manufacturing

We not only predict anomalies but also the effects of those defects on the final product. Digital Twin technology based on fundamental material science is in our DNA.

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Simulate With Confidence & Build to Precision

…From Powder to Part

Our Integrated Computational and Materials Engineering (ICME) approach bridges the gap between material science and finite element analysis making digital twin technology a reality

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Developed for the US Department of Defense…

…Commercialized for the People

Over three decades of supporting the nation’s Warfighters

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Enabling Best-in-Class Polymer AM Capabilities Through Siemens Digital Industries

SIEMENS

Bringing our micromechanics digital twin technology for polymer 3D Printing build simulation to Siemens customers worldwide

SIEMENS

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Serving Leading Companies Globally

We have deployed our technology in over 20 Countries Worldwide with Partner Channels in APAC, EMEA, and North America

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Toolpath
Simulation on the World’s Most Ubiquitous Polymer AM Platform

Now available as a plug-in to GrabCAD Print Pro™

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Award-winning

Industry-validated

Acknowledged by the Scientific Research Community

Award-winning

Industry-validated

Acknowledged by the Scientific Research Community

Cutting-Edge Simulation Software to Enable a New Era of Manufacturing

Grounded in Advanced Material Science That’s Made Simple and Accessible
True Physics-Based Analytical Solution for High-Resolution and Computationally-Efficiency
Verified, Validated and Implemented
Based on 30+ Years of Advanced Research Addressing Mission-Critical Challenges
Comprehensive Simulation Toolset for Advanced Material Modeling, Advanced Manufacturing, Virtual Testing and AM Process Optimization

AlphaSTAR’s ICME Approach

Integrated Computational Materials Engineering

In modern engineering, revolutionary products are dependent on revolutionary material systems. Whether pursuing hypersonic applications, deep ocean energy extraction, or extremely sensitive medical devices, understanding materials, predicting material behavior, and establishing material databases are the foundation for successful product development.

Multi-scale Progressive Failure Analysis

We not only predict anomalies but also the effects of those defects on the final product. Digital Twin technology based on fundamental material science is in our DNA.

Material Characterization and Qualification

Build
Simulation
for Additive
Manufacturing

AlphaSTAR’s ICME Approach

Integrated Computational Materials Engineering

Material Characterization and Qualification

We not only predict anomalies but also the effects of those defects on the final product. Digital Twin technology based on fundamental material science is in our DNA.

Build
Simulation
for Additive
Manufacturing

Additive Manufacturing Simulation –
Powered by AlphaSTAR’s Thermo-Mechanical
AM Part Qualification

Build Preparation / Design / Meshing

- Design / import CAD geometry
- Set up build tray and generate toolpath
- Create structural mesh or use automatically generated voxel mesh

Material
Modeling

- Develop materials for AM specific applications
- Generate anisotropic properties for material qualification
- Predict mechanical properties for metals, i.e., fracture/fatigue

Thermal Process Simulation

- Toolpath driven thermal history
- Considers g-code, and variable print parameters

Raster Air Gaps Assessment

- Predict slicing or coverage gaps from toolpath raster
- Map macro-voids to structural analysis
- Used for process simulation and in-service load analysis

Mechanical Build Simulation

- Map transient temperature distributions to FE mechanical model
- Predict defects during print, and effect of defects on part performance

Reducing Trial & Error of Conventional
Manufacturing Processes

AlphaSTAR tools provide a digital blueprint or “digital twin” of the part
being built before production even starts

Where Fits Into
Conventional AM Workflows

Highly-Adaptable Simulation Technology to
Address a Variety of Use Cases in Traditional
Advanced and Additive Manufacturing

Materials

Polymers
Composites
Metals
Ceramics

Loading Conditions

Static
Impact
Fatigue

Available Platforms

Stand-alone Tools

Embedded Into Build Prep Software

Extensions to Traditional FEA Packages

Manufacturing Processes

3D Printing
Injection Molding
Compression Molding
Filament Winding

End Use

Tools for Engineering Departments
Down To Shop Floor Practitioners

Part-Size

Applicable to Macro-sized Parts Down to Nano-level Material Particles

FE Partners

Applications

While its legacy has been in serving the US Department of Defense, NASA, multiple federal agencies and leading US defense
contractors in mission-critical applications, today AlphaSTAR works with product designers, product developers, and manufacturers
from all walks of life to address a multitude of applications and functional challenges with broad market potential.

Target Verticals

Government & Defense

Space & Aeronautics

Consumer Products

Energy

Automotive

Medical

Target Applications

Supports continuous / discontinuous polymer and ceramic matrix composites
Reverse engineer constituent properties
Considers effect of defects
Generates material cards as input into FE solvers

Augments traditional FE solvers to predict behavior of advanced composite materials and structures subject to various loading conditions (static, fatigue, impact, environmental
Combination of an as-built de-homogenized material model and multi-scale progressive failure analysis
Integrates damage initiation, material degradation and fracture evolution
Track damage initiation and propagation until final failure

Thermo-mechanical virtual AM part qualification
Build process simulation for powder bed fusion and material extrusion additive methods
Predict defects and distortions during the build, and effect of defects on mechanical behavior