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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
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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.

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.

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.

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.

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.

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.

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

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

AlphaSTAR Solutions

  • 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

  • Subset of our Genoa3DP (toolpath simulation)

  • Parameter driven powder to part thermal AM Simulation

  • Considers g-code / toolpath and variable layer thickness

Trusted by Blue Chip Institutions Across the Advanced Manufacturing Ecosystem

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