Aerospace Bracket
- Material
- Ti64
- Overhang
- down to 20°
Industry
Thermally demanding flow components
Impellers, manifolds and heat exchangers have exactly the mass distributions where heat accumulates. Where heat flow is visible before the build, distortion can be steered rather than corrected.
What makes this industry difficult
Closed impellers with curved blades, thin walls and internal flow surfaces are thermally difficult: overhangs and mass concentrations create uneven heat and distortion risk. Internal supports are also close to impossible to remove.
What GENESIS does
Where the physics pays off
Heat accumulation visible before the build
Fast Heat Simulation shows the intensity and extent of overheated regions, layer by layer.
Locally adapted strategy
Smart Hatching steers heat away from critical zones instead of treating them afterwards.
Fewer internal supports
Precisely where manual removal is most expensive, or impossible.
Typical parts
Radial impellers · manifolds · heat-exchange geometries · turbine components
In practice
A part from this industry
Radial impellers · manifolds · heat-exchange geometries · turbine components
On the reference part
16 s
thermal simulation, IN718
625
layers simulated
20°
support-free overhang
Radial impeller, 164 × 79 × 25 mm, printed on an SLM 500 at the Danish Technological Institute.
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
How accurate is the fast simulation?
It is built to identify critical regions reliably and derive a strategy from them — not to replace an FEM result. The difference is seconds instead of hours, which is what makes it usable on every build job.
Does it work on closed geometries?
Yes. On test geometries, closed spheres with 0° overhangs were printed with no internal supports at all.
Which nickel-base materials are demonstrated?
IN718 down to 15° support-free overhang, from the OEM technology evaluations.
Does it reduce residual stress too?
More even thermal conditions act on the causes of distortion and residual stress. How much is part- and material-specific — we work that through on your part.
Ready to get started?