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
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Simulation and Optimization for Wire Laser Additive Manufacturing.
Digital Twin in Action
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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.
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