FLOW-3D 2025R1 Expands Simulation Capabilities for Additive Manufacturing and Welding Processes

With the release of its FLOW-3D 2025R1 software suite, Flow Science introduces two specialized applications for the numerical simulation of additive manufacturing and precision welding: FLOW-3D AM and FLOW-3D WELD. These new tools address key challenges in the development, validation, and optimization of laser-based manufacturing processes and are fully integrated into the existing FLOW-3D platform.

FLOW-3D AM 2025R1 is tailored for users looking to simulate and analyze processes such as Powder Bed Fusion (PBF) and Directed Energy Deposition (DED). The software features a unified user interface with pre-configured process templates, enabling standardized parameter setups and significantly shorter preparation times. With High Performance Computing (HPC) support, simulation runtimes can be reduced by up to a factor of nine compared to traditional workstations, according to the manufacturer. This performance boost facilitates extensive parameter studies essential for qualifying new materials and optimizing processes.

FLOW-3D WELD 2025R1 also benefits from an improved interface and offers templates for various welding methods, especially laser beam welding. The software allows simultaneous activation of all relevant physical models within a single application and supports the management of different material combinations. When combined with FLOW-3D (x), users can implement automated workflows for model validation, sensitivity analyses, and process window studies.

“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.”

In addition, FLOW-3D 2025R1 introduces a Discrete Element Method (DEM) model for the realistic simulation of particle-based flows. This addition enables new applications in powder mixing, particle deposition, and material flow behavior in additive manufacturing.

With this latest release, Flow Science continues to pursue its strategy of providing realistic modeling of complex physical processes in manufacturing, while making numerical simulation more accessible through automation and enhanced user guidance. Full HPC support reinforces the aim of drastically reducing simulation times, making development cycles in additive manufacturing significantly more efficient.