ÂÌñÏ×ÆÞ

Multiphysics Process Optimization (MPO), a software feature using physics based G-Code postprocessing added to ’s (Montreal, Quebec, Canada) Hylo 3D printer — capable of using chopped carbon, glass and Kevlar fibers — has enabled the company to cut print times by as much as 54%, without compromising part quality or performance.

“Until now, polymer physics have been left out of the slicing process, relying solely on trial-and-error tuning — a time-consuming process with variable outcomes,” says Adrian Muresan, AON3D VP software research.

The MPO module is combined with AON3D Basis real-time part qualification software. Using a physics-based model of each polymer’s rheological and thermal properties, AON3D’s Throughput Optimization Module analyzes G-Code to determine how heat will build and dissipate through a part. The software dynamically adjusts deposition rates based on part geometry to achieve the fastest possible print speeds without exceeding a material’s melt-fracture limits, and before inducing overheating deformation. By coupling rheology and heat transfer properties, the system automatically accelerates when conditions allow and slows down when necessary to maintain surface finish. The result is maximum throughput without compromise: faster prints, consistent layer bonding and smooth, repeatable parts every time. In testing, the software was able to cut 13 hours off a 24-hour print.

According to the company, other systems on the market achieve faster printing through larger nozzles, which diminish surface finish, and requires trial-and-error tuning — turning up print speeds, feed rates and extrusion temperatures until quality begins to fail, then backing off slightly. These settings are applied globally, regardless of part size, geometry and cooling conditions; when applied to unique geometries, this one-size-fits-all approach often results in drooping/poor surface finish, due to overheating, and unpredictable anisotropy due to variations in weld strength.

AON3D Hylo is a large, high-throughput, high-temperature industrial 3D printer built for manufacturing — enabling same-day, full-scale production of end-use parts and tooling. The platform is paired with AON3D Basis. Applying MPO, Basis dynamically tunes print settings based on part geometry and polymer. In addition, Basis features real-time part qualification software with in situ defect detection. Combined, the Hylo and Basis provide ultra-high throughput; high-quality parts with maximized properties; reduced skilled labor requirements; and ultra-low operating costs (up to 600% lower OPEX versus closed material systems).