Home Software Aibuild Integrates Thermal FEM Simulation into Software for Large-Format 3D Printing

Aibuild Integrates Thermal FEM Simulation into Software for Large-Format 3D Printing

Picture: Aibuild

UK-based software company Aibuild has introduced a new solution addressing the need for precise thermal management in Large Format Additive Manufacturing (LFAM). Now available in beta testing, the new feature integrates finite element (FEM)-based thermal simulation directly into toolpath planning, with primary applications in Direct Energy Deposition (DED) and large-scale polymer extrusion.

“After a decade of rigorous testing in our Ailab and close collaboration with manufacturing partners across the globe, we’ve seen the same thermal challenges halt true WAAM success. This release represents the culmination of 10 years of deep industry knowledge and our commitment to advancing additive manufacturing across processes and applications,” said Daghan Cam & Michail Desyllas, Co-founders.

Until now, thermal control in LFAM processes has largely relied on experience-based heuristics and manual adjustments. In practice, this often leads to defective parts, material waste, and production interruptions. Aibuild’s solution aims to replace this reactive approach with a simulation-driven workflow. The software automatically generates a finite element mesh based on printing parameters, material properties, and environmental conditions. It then visually simulates the thermal evolution during part fabrication, optimizing toolpath speed, dwell times, and process parameters—all before printing begins.

“Our engineering team is the brains behind this solution. Combined with insights from our partner network, we’ve built something that fundamentally changes how manufacturers approach thermal simulation in WAAM. This really is manufacturing software built by engineers, for engineers,” said Jack Sandiford, Product Manager.

The beta version is being tested with select partners from the metal and polymer processing industries. General availability of the simulation module for all LFAM users is planned for Q3 2025. With this release, Aibuild is positioning itself as a provider of simulation-based software solutions that aim to make industrial additive manufacturing more efficient and predictable.


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