Aerospace Bracket
- Material
- Ti64
- Overhang
- down to 20°
Industry
Additive serial production for aerospace
Certified lightweight parts with steep overhangs are exactly the geometries that make conventional build preparation expensive. GENESIS predicts the thermal behaviour and adapts the exposure strategy before machine time is spent.
What makes this industry difficult
Structural parts, brackets and tanks are designed topology-optimised — and those shapes produce overhangs that conventionally print only with extensive support structures. Every support costs powder, build time and rework, and every failed build costs the whole job.
What GENESIS does
Where the physics pays off
Steep overhangs without supports
Support-free overhangs down to 20° achieved in Ti64 on an SLM 500. Conventional practice sits at roughly 45°.
Less rework on surfaces you cannot reach
Fewer supports means less manual removal inside geometries that are barely machinable.
Repeatable across parts
The method transfers to new geometries instead of living in one engineer's experience.
Typical parts
Structural brackets · satellite tanks · ducting · topology-optimised consoles
In practice
A part from this industry
Structural brackets · satellite tanks · ducting · topology-optimised consoles
What a serial part saves
−95 %
support volume
−29 %
cost per part
20°
support-free overhangs, Ti64
Topology-optimised bracket in serial production: 29% lower cost per part, 0.5 instead of 8 hours of support removal per build job.
Renowned universities and companies trust GENESIS
Built with GENESIS
Real parts, prepared in GENESIS and printed on production machines.
Tube & Plates
- Material
- Ti64
- Overhang
- down to 21°
Sphere
- Material
- Ti64
- Overhang
- down to 0°
Spiral
- Material
- Ti64
- Overhang
- down to 20°
Impeller
- Material
- Ti64
- Overhang
- down to 20°
Separator
- Material
- 316L
- Overhang
- down to 30°
Satellite Tank
- Material
- AlSi10Mg
- Overhang
- down to 20°
What you are trying to solve
Support-free printingSupport structures are not a design feature. They are a consequence of uncontrolled heat — and steering heat flow before the build removes most of the need for them.Distortion controlDistortion does not happen at random. It follows the heat distribution in the part — and that can be computed and influenced before the build.Process stabilityOn high-power machines, thin walls and sharp corners have forced a compromise: productivity or quality. Locally controlled laser power removes that trade-off.Serial productionSerial production starts where unit costs can be calculated. Deterministic process behaviour is the precondition — and the point at which prototyping becomes production.QualificationBringing a new machine and material combination into service is normally a project. With GENESIS it is a calibration with a clearly defined scope.
Frequently asked questions
Is this enough for qualification?
GENESIS gives you the deterministic, explainable calculation a qualification builds on — it does not replace one. Calibrating to your machine and material takes two factors and two build jobs, thermal and mechanical.
Does it work with our certified process parameters?
Yes. Smart Hatching takes the approved OEM process parameters as boundary conditions and changes the exposure sequence and orientation, not the parameters themselves.
Which materials are demonstrated?
Ti64 to 20°, IN718 to 15°, AlSi10Mg to 14°, AlSi7Mg0.6 to 25°, from technology evaluations across seven OEM platforms.
How fast is the simulation in practice?
A full thermal simulation of an IN718 impeller across 625 layers takes 16 seconds. Preparing a complete build job takes 82 seconds. That makes simulation part of daily work rather than a separate study.
Can we automate it?
Yes, through the GENESIS API, which brings simulation and strategy generation into automated manufacturing pipelines.
Ready to get started?