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Left: Simulated temperatures during the end of the printing process, Right: IR camera, measured temperatures during the end of the printing process I printed a little triangular bracket in six and a half minutes. Then I spent the better part of a day watching a solver re-live every second of it, element by element — and learned more about why prints fail than a hundred successful prints had taught me. Every hobbyist who runs a 3D printer eventually develops a sixth sense for

The same CoCr partial, two support philosophies, straight off the plate. Left: lattice supports — a connected cross-hatch network that clamps the broad spans rigidly and pulls heat out evenly, at the cost of more contact to clean up. Right: tree supports — slender branches that touch the framework only at their tips, sparing the surface and clipping away fast, but far springier against the thermal pull on thin clasps and rims. You can read the trade-off in the metal itself: t

Side-by-side comparison showing the matching displacement magnitude of a structural hinge, featuring a simulation result on the left and an experimental 3D scan on the right. Anyone running a metal powder bed fusion (LPBF/DMLS) system knows the sinking feeling of opening the build chamber only to find a curled baseplate, a part out of tolerance, or a shattered recoater blade. Metal additive manufacturing delivers incredible geometric freedom, but it comes bound to severe phys

Residual stresses and the resulting macroscopic deformations remain the most costly barriers to first-time-right metal additive manufacturing. During processes like Selective Laser Melting (SLM), extreme temperature gradients and rapid shrinkage often lead to part rupture, re-coater crashes, or severe dimensional inaccuracies. While transient thermo-mechanically coupled analyses can simulate these phenomena, they are notoriously slow, often requiring days or weeks of computat

Modern firearm suppressors have evolved from simple stacked-washer tubes into complex, monolithic flow-through suppression systems. Intricate internal helical channels, variable-density gyroids, and optimized expansion chambers allow modern suppressors to cut backpressure, mitigate muzzle flash, and drop decibel levels without adding dead weight. Machining these tortuous internal geometries with multi-axis CNC or EDM is either economically unfeasible or geometrically impossib

NODiVEC LLC Launches Rheona™: A Physics-Grade Simulation Platform for Metal Additive Manufacturing NODiVEC LLC has unveiled Rheona™, a groundbreaking simulation platform designed for metal additive manufacturing (AM). This affordable desktop application integrates structural, thermal, and sintering physics. It features an on-device AI advisor and can solve models with millions of elements on standard laptops and PCs. NODiVEC redefines simulation delivery, allowing engineers t

We are absolutely thrilled to announce that NODiVEC has been officially selected as a finalist for the 2026 InnoVision Awards in the Technology Integration category. Since 1999, the InnoVision Awards have served as the benchmark for celebrating impactful, forward-thinking innovation developed right here in South Carolina. To be recognized among the state’s most dynamic and transformative organizations is a profound honor that validates the hard work, technical rigor, and visi

At NODiVEC, the development philosophy behind Rheona™ has always prioritized direct, transparent communication and accessible, production-focused tools over heavy, opaque academic research packages. A solver is only as good as its validation. To prove Rheona’s capabilities, we put it up against the gold standard in AM validation: the NIST AM-Bench 2022-01 (AMB2022-01) challenge. Here is an honest, data-driven look at how Rheona handles complex macroscopic distortion. The Chal

We are incredibly proud to announce that our Founder, Dr. Christian Rossmann, has officially graduated from the Launchpad Tech Ventures accelerator program! At the culmination of the cohort, Dr. Rossmann and NODiVEC were honored to take home two major recognitions: 🏆 The Dan Roselli Award for Most Fundable 🏆 The Best Mentor Award Building the NODiVEC Rheona™ platform—physics-grade simulation and AI decision-support tools for metal additive manufacturing—is a highly complex

In metal Additive Manufacturing (AM), physics-based simulation has traditionally been treated as a luxury—a slow, complex, late-stage validation step reserved strictly for high-stakes, mission-critical components. But as our Founder and CEO Christian Rossmann highlighted in a recent feature interview with 3Druck.com, this traditional paradigm is holding the industry back. To make metal 3D printing truly scalable and viable for standard production, physical simulation needs to

In metal Additive Manufacturing (AM)—particularly processes like Laser Powder Bed Fusion (LPBF)—extreme thermal gradients are unavoidable. As molten metal rapidly heats and cools, localized thermal expansion and contraction generate severe internal stress. When the part is printed, cut from the build plate, or stress-relieved, these internal stresses release, causing the geometry to twist, bow, or warp out of tolerance. Distortion compensation is the proactive answer to this

If you’ve spent any time working in metal additive manufacturing (AM), you know the sinking feeling of a failed build. It’s never just about the wasted powder. A failed metal print means days of lost machine time, thousands of dollars down the drain, and a domino effect of delays across your entire production schedule. Yet, despite these high stakes, much of the industry still relies on a "trial and error" approach to get things right. I recently had the pleasure of joining t

Below we share how we simulate complex thermal histories during Directed Energy Deposition (DED) additive manufacturing using the Rheona™ software platform! 🚀 In this quick demo, we analyze a complex Stainless Steel (316) lattice structure to evaluate transient temperature fields and thermal loads during the building process. Key Highlights of the Workflow: Geometry Import & Meshing: Seamlessly importing CAD models and generating volumetric meshes optimized for thermal analy

As we continue to push the boundaries of metal additive manufacturing simulation, validating our high performance FEM solvers against established, rigorous academic frameworks remains a top priority. A critical milestone in this ongoing process is accurately predicting macro-scale thermal deformations in Laser Powder Bed Fusion (LPBF) before physical production begins. To test our capabilities, we turned to the foundational research presented in Verzugsminimierung bei selekti

For those unfamiliar, the VTT pipe case study has been around for quite some time and contains an in-depth description of the additive manufacturing process of a pipe geometry, alongside comprehensive post-manufacturing measurements. This makes it an excellent benchmark for AM process simulation software. (Note: The pipe test geometry provided by VTT can be accessed from their website. The design was manufactured with H13 tool steel via Selective Laser Melting (SLM)). The man

ColdMetalFusion (CMF) is unlocking new possibilities in additive manufacturing by combining the geometric freedom of 3D printing with the proven robustness of powder metallurgy. However, the sintering phase introduces a critical hurdle: part shrinkage and distortion. As the green part densifies in the furnace, complex geometries warp, causing out-of-tolerance failures. To demonstrate how to address this challenge, we virtually predicted the behavior during and after the sinte

Displacement magnitude after sintering. When you print a metal part with a sinter-based process like Cold Metal Fusion (CMF) or Metal FFF, the printer is only the first act. The green part that comes off the build plate is metal powder glued together with polymer binder. It then gets the binder cooked out and the bare powder fused in a furnace — and during that furnace cycle the part shrinks by around 14% and, if it was designed badly, can sag, distort, or collapse under its

Mastering Sinter-Based Additive Manufacturing with Predictive Simulation Sinter-based additive manufacturing processes, such as Metal Binder Jetting (MBJ), Metal Injection Molding (MIM), and Cold Metal Fusion (CMF), are revolutionizing the way we produce complex metal components. By decoupling the shaping of the green part from the metallurgical bonding of the metal, these technologies offer unprecedented scalability and design freedom. But there is a catch: the furnace is a

We are excited to share that NODiVEC has officially joined Launchpad! We are building Rheona™ to tackle the fundamental inefficiencies in metal additive manufacturing. By pairing high-speed physics simulation with deterministic AI, we are eliminating the costly trial-and-error cycles that slow down production. Join us at launchpadtv.com to see what we're working on. #NODiVEC #AdditiveManufacturing #PhysicsSimulation #Launchpad

Legacy simulation tells you where a complex part will fail. It doesn't tell you how to fix it. At NODiVEC, we are eliminating the multi-million dollar "failure tax" by shifting the industry from raw data generation to Automated Decision Support. Meet Rheona™: our new software ecosystem that pairs a high-speed, workstation-native FEM physics engine with the CoEngineer™—a deterministic AI agent that translates complex thermal and stress fields into instant, mathematically certa