Investigated baseline
Time / part
65.1 min
Cost / part
$43.81
Annual time2,600 h
Annual cost$105k
Published production-scale case
How much did we save with a WLAM digital twin?
In the validated flange case, simulation-guided parameters reduced deposition time and the direct variable cost of material, shielding gas and electrical energy—without separating process economics from manufacturing quality.
1,860 h
machine time difference per year
$68k
annual variable-cost difference
Digital-twin optimized
ValidatedTime / part
18.5 min
Cost / part
$15.58
Annual time740 h
Annual cost$37k
Approximately 72% less deposition time and 64% lower variable cost per part
Based on 2,400 flanges per year. The dominant saving in this case came from reduced shielding-gas time, with electrical energy also contributing. These figures describe this published validation case—not a universal guarantee or full TCO calculation.
Real World Use Cases
From Simulation to Defect-Free Production
See how our physics-based simulations predict outcomes and optimize process parameters before production.
Predict Deposition Defects
Precisely tune laser power, feed rate, and robot motion to achieve consistent, high-quality deposition.
Instantly detect process defects and eliminate trial-and-error — all driven by a high-fidelity digital twin.
Powered by:
Baal Hammon MultiPhysicsOur SPH based Multi Physics Deposition Solver
Digital Twin In Action
Simulation and Optimization for Wire Laser Additive Manufacturing.
Digital Twin in Action
The demo video is loading.Parameter Optimization
Find the Perfect Process Settings
Analyze multiple parameter combinations. Eliminate guesswork, reduce material waste, and maximize build quality for your metal additive manufacturing process.
Digital Twin Simulation
Simulate, Predict, Perfect
Layer-by-layer simulations of your metal AM process give you accurate insights into melt pools, heat flow, and material behavior — so you can print with confidence.
Process Window Detection
Find Stable Parameters, Every Time
Detect optimal process windows to ensure consistent part quality, prevent defects, and guarantee build integrity.
Bring your process into the digital twin
Tell us about the production challenge, robot cell or additive process you want to optimize.