Published by:

Nina Korshunova

Published on:

Jan 25 2022

Reading Time:

3 minutes

The engineering community is a tough cookie. And, if anyone tells you otherwise, don’t believe it. The hard truth is that engineers like to pose questions. And, rightfully so: this is how they find solutions to the most sophisticated problems. Without this mindset, there won’t be a breakthrough in industrial development, disruptive changes in the existing processes, or simply better solutions. I am an engineer myself. And I sincerely understand the necessity of these questions. So, today I would like to answer one of them.

Can our software, ReveaL, compete with existing commercial solutions? We heard many times that our solution solves a lot of engineering pain for cases where the available model is non-watertight or exists only in a form of a computed tomography recording. But, can ReveaL deliver the same results for a standard use case while keeping up with the performance? Well, let’s give it a go. Let’s challenge ReveaL in accuracy, time and memory.

Challenge of lattice structures

In a frame of a pilot project with Siemens, we were confronted with the following challenge. We were offered to take a simple use case in industrial 3D printing: a sandwich structure with lattice between two plates. When we increase the size of this structure, a conventional FEM solver starts being more expensive in terms of meshing and solving times.

Case 1: BCC with 2x2x1 unit cells
Case 2: BCC with 4x4x2 unit cells
Case 3: BCC with 6x6x3 unit cells
Case 4: BCC with 8x8x4 unit cells

 

Our partner at Siemens simulated these lattices under torque using their conventional commercial software while we provided them with the results of ReveaL. We agreed on comparing four main quantities: average stress arising in one diagonal strut, average stress in the whole lattice, simulation time and peak memory. Similar workstations, same setup – same challenge.

…Drumroll…

ReveaL is a competitive software!

“Eh?! How is it possible?” – would you ask, – “The software is so young!” Yes, we are a young startup, but our technology is mature.

Let’s look at the numbers. For a medium size of the lattice Reveal showed the following results:

Case 3, quadratic elementsCommercial softwareReveaL
Degrees of freedom4.9 Million4.84 Million
Wall clock time (run time)532 s583 s
Maximum memory41.8 Gb64.8 Gb
Corner distortion86 µm92 µm
Average stress in a diagonal strut107 MPa109.5 MPa
Average stress in the lattice141 MPa144.9 MPa

Looks promising? Yes! And this is just the tip of the iceberg, you can read more details about this use case in our whitepaper:

What is in it for you?

Of course, we have still a lot to improve, a lot of features to build. But we can say already now that ReveaL is a simulation tool which is fast, reliable and accessible. The outstanding advantage of using ReveaL to perform simulation is that it works for any type of geometrical models: non-watertight CAD, point clouds or CT scans. It is agnostic to the input geometry and its quality. This allows to reduce computational costs, remove manual effort and explore designs that were never feasible for simulations before.

We at DirectFEM do not provide yet another STL repair tool, we offer a standalone software, ReveaL, that allows to simulate directly on the provided geometry removing the step of geometry reconstruction and healing. And, as you see, for a standard case, ReveaL performs at least as good as commercial tools or even better.

Do you want to try?

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