Additive Manufacturing Optimize 3D-Printed Parts With Fewer Trial-And-Error Tests

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Stratasys GmbH

Wuxi InfiMotion Technology Co., Ltd.

Stratasys has integrated Novi-Path, a validated simulation solution for polymer performance from Novineer, into the GrabCAD Print Pro software. This allows engineers to design lighter, stronger parts with predictable performance more quickly and cost-effectively, while reducing the need for physical testing for safety-critical, load-bearing applications.

Novineer's technology uses GrabCAD toolpath data to simulate part behavior in real applications. The software takes into account build orientation, layer direction, infill patterns, and material-specific properties. This solution provides predictive accuracy, enabling weight reductions of up to 35 percent for load-bearing parts, according to initial customers.

"The partnership with Stratasys anchors Novi Path's toolpath-aware part simulation in GrabCAD Print Pro and bridges the gap between design intent and real part performance," said Ali Tamijani, Ph.D., CEO and co-founder of Novineer, Inc. "Stratasys users can now predict stiffness, strength, and failure before clicking 'print'—reducing trial and error, time, and cost, and enabling the qualification of additional FDM parts. As the first OEM to introduce this unique solution, Stratasys is redefining what material extrusion can achieve in production."

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Engineers often overdesign FDM parts or rely on trial-and-error tests due to the lack of an easy-to-use, accessible simulation for predicting part performance.

Victor Gerdes, Vice President, Software, Stratasys

Precise Predictions of Stiffness, Strength, And Failure Behavior

Traditional finite element tools treat 3D-printed parts as homogeneous components and ignore the layered nature of material extrusion. As a result, accurate predictions of the behavior of extruded parts in real-world applications are not possible with conventional FE tools. The integration of Novineer uses process-informed GrabCAD data to provide accurate predictions of stiffness, strength, and failure behavior.

"Engineers often over-engineer FDM parts or rely on trial-and-error testing because they lack an easy, accessible simulation to predict part performance," said Victor Gerdes, Vice President, Software, Stratasys. "By integrating Novineer simulation into GrabCAD Print Pro, engineers can predict the behavior of FDM parts before printing—saving time and costs. It is a complete, validated workflow for polymer extrusion that no other 3D printer manufacturer offers today."

Identify Failure Points And Load Limits Before Printing

Novi-Path works with GrabCAD Print Pro, allowing users to run simulations using the same toolpath data that will later be used to print FDM parts. Engineering teams can define application-specific load cases and safety factors, identify likely points of failure, and iterate virtually until performance requirements are met—all while staying entirely within the Stratasys software environment.

With the Novineer integration, Stratasys expands its ecosystem to cover the entire engineering workflow for industrial FDM printing solutions—from design and print preparation to performance validation and production. The combined solution offers engineering teams:

• The ability to identify failure points and load limits before printing
• Proven accuracy with weight reductions of up to 35% on critical parts while maintaining part quality
• Faster time-to-production, reducing validation from weeks to hours
• Lower overall costs through lighter parts, shorter build times, and elimination of time, costs, and iterations for test parts

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