FLOW-3D

Zinc-coated steel is everywhere in automotive manufacturing, but laser welding it creates a problem: zinc vaporizes before steel melts, causing spatter and porosity that compromise weld quality. This FLOW-3D WELD simulation demonstrates laser lap welding of galvanized steel, capturing how zinc vapor pressure builds up at the interface and causes explosive spatter as vapor pockets escape. By modeling zinc vaporization dynamics, engineers can test different process parameters to find conditions that minimize spatter and porosity in automotive body assembly and other galvanized steel applications. Dealing with zinc-coated steel welding challenges? Schedule a demo to see how FLOW-3D WELD can help you optimize your process parameters. #flow3dweld #laser #cfd

How do you validate bridge hydraulic assessments when the stakes are flood safety? Queensland's Department of Transport and Main Roads presented their approach to improving accuracy in bridge design through FLOW-3D HYDRO modeling. At our 2023 World Users Conference in France, DTMR presented two case studies: first, comparing simulation results against observed flood levels to develop improved form loss coefficients for large-scale flood modeling. Second, optimizing bridge substructure layout to minimize hydraulic losses in a new design. Both examples demonstrate how detailed CFD analysis supports better engineering decisions when standard approaches fall short. You can find DTMR's full presentation slides on the FLOW-3D Conference Proceedings site: flow3d.com/conference-pro… #flow3dhydro #cfd #bridgedesign

Joining dissimilar materials in battery manufacturing is challenging due to varying thermal properties. In busbar welding, aluminum and copper need to fuse without creating brittle intermetallics or excess porosity, all while meeting tight dimensional tolerances. This FLOW-3D WELD simulation captures how aluminum and copper mix in the melt pool, how heat distributes through both materials, and how the joint solidifies. This visibility helps engineers avoid intermetallic compounds at the joint interface, spatter from uncontrolled melt pool dynamics, and porosity that degrades both electrical and mechanical performance. Simulation lets you test parameter combinations (laser power, travel speed, scan path, spot size) before running physical trials, mapping out viable process windows and identifying problem areas early. This significantly reduces iteration cycles when dialing in new processes or scaling from development to production. Want to learn more about the physics behind busbar welding and see what the industry is doing? 🔅Research paper on laser welding for battery busbars: sciencedirect.com/science/articl… 🔅IPG Photonics on battery module busbar welding solutions: ipgphotonics.com/en-us/solution… #flow3dweld #cfd #batterymanufacturing

When you're investing in tooling and production setup, simulation accuracy isn't negotiable. Where you place overflows depends entirely on how accurately your simulation predicts metal flow behavior. This high pressure die casting simulation shows a back-to-front filling pattern. This flow behavior has direct implications for overflow placement. When metal jets across the cavity and fills backward toward the gate, overflows may need to be positioned near the gate itself rather than at the far side of the casting. Accurate prediction of this jetting behavior is critical for effective overflow design. Detailed velocity visualization throughout the filling sequence helps engineers place overflows where metal will actually be during filling. This level of flow prediction accuracy supports confident tooling decisions before committing to production. #flow3dcast #cfd #hpdc

Understanding how material and process parameters influence melt pools and outcomes is essential in metal AM development. The FLOW-3D AM workshop at LIFT guides participants through CFD exercises that give practical experience connecting simulation results to process windows, defect formation, and parameter sensitivity. This one-day workshop, taking place on February 19th in Detroit,  emphasizes applied learning, peer discussion, and direct interaction with FLOW-3D AM experts. Space is limited to ensure a focused, hands-on environment. Here’s a link to the LIFT event: lift.technology/icme-in-action/ And the link to register for the FLOW-3D AM workshop: flow3d.com/flow-3d-am-wor…

When CFD modeling is validated against physical data, it becomes a tool for evaluating multiple design scenarios and operational conditions without the expense of building additional physical models. This case study of the Garrison Dam’s spillway and outlet works validated FLOW-3D HYDRO models against experimental data from the US Army Corps of Engineers Omaha District. The comparison shows strong agreement between numerical and physical model results across discharge, water surface elevation, and pressure in both gated and ungated conditions. Schedule a demo or register for an upcoming workshop to learn more about how you can use FLOW-3D HYDRO to make reliable design decisions. #flow3dhydro #cfd #damdesign

This FLOW-3D AM simulation illustrates a laser beam with a ring-shaped heat flux distribution moving along a track during a laser powder bed fusion (LPBF) process. Metallic powder particles are melted as the beam advances, providing a detailed view of melt pool dynamics. What makes this visualization distinct is the use of FLOW-3D POST’s ray tracing capabilities, which capture metallic light refraction to more realistically represent material behavior. 👉 What role do you see advanced visualization playing in improving additive manufacturing process understanding? #flow3dam #lpbf #cfd

We are pleased to announce that the FLOW‑3D European Users Conference 2026 will take place on the 16th – 17th of June in Düsseldorf, bringing together the user community of engineers and researchers employing the FLOW‑3D product family across Europe and beyond. Registration is open, so mark the dates and join us for two days of technical engagement and community building. flow3d.com/flow-3d-europe… #euc2026 #flow3d #cfd

Throwback Thursday to Stuttgart 2018! Here's a moment from the FLOW-3D European Users Conference opening reception at the beautiful Le Méridien hotel. It was a wonderful evening of conversations and connections among the FLOW-3D community. We can’t wait to create more memories this year! Join us in Lisbon at the FLOW-3D European Users Conference 2025 for a rooftop reception, engaging technical presentations, and plenty of opportunities for discussion and learning. 🚨 Registration is open through May 16. flow3d.com/flow-3d-europe… #ThrowbackThursday #euc2025 #flow3d #cfd

How can simulation improve melt pool control in metal AM? A recent article from 3D Printing Industry features a study presented at AMUG 2025, in which researchers used FLOW-3D AM to model the effects of ring-shaped laser beam profiles on titanium alloy builds. The results closely aligned with experimental data, showcasing the power of simulation in capturing complex melt pool behavior. Read the full article here: 3dprintingindustry.com/news/flow-3d-a…

How can simulation accelerate material development in aerospace manufacturing? Join Garrett Clyma at AeroMat 2025 as he presents how FLOW-3D AM is being used to reduce trial runs, save on capital costs, and speed up the path to qualification for new materials. 🕣 Wednesday, May 7th | 8:30 AM 📍 Room 14, Vancouver Convention Centre If you’re attending Aeromat and would like to learn how FLOW-3D AM can support your additive manufacturing goals, schedule a meeting with Garrett during the conference. 🔗flow3d.com/aeromat-2025-p… #aeromat2025 #flow3dam #cfd

Planning to attend the 2025 USSD Annual Conference in Kansas City? Stop by booth 112 and meet our FLOW-3D HYDRO team. You’ll have the opportunity to speak directly with two of our leading experts in hydraulic modeling: 🔹 Dr. Dan Gessler, Global Water Infrastructure Lead Dan brings decades of experience and a passion for helping engineers maximize the value of CFD in their work. His vision is to equip engineers with the tools and skills to tackle complex water infrastructure challenges with confidence. 🔹 Brian Fox, Senior Applications Engineer With over 15 years of experience in water and environmental modeling, Brian supports engineers across sectors with advanced hydraulic modeling, including fish passage, sediment transport, and analysis of hydraulic structures. Interested in a one-on-one conversation? Schedule a meeting with our team and explore how FLOW-3D HYDRO can support your hydraulic modeling goals: flow3d.com/ussd-2025/ #USSD2025 #flow3dhydro #cfd

Thanks to everyone who attended Garrett Clyma’s presentation at AMUG 2025, where he spoke about the role of laser beam shaping and CFD modeling in improving process control for additive manufacturing. Want to see where we’re headed next? Garrett will be presenting again at AeroMat 2025—check out our events page for more details and other upcoming events. flow3d.com/events/ #flow3dam #cfd #AMUG2025 #AeroMat2025

One day left at CastExpo 2025! If you haven’t stopped by yet, Joel Jacob and Nathan LeBlanc are at booth 2637—come by and talk casting simulation with us. #flow3dcast #cfd #foundry

Planning to attend the Florida Water Resources Conference? Stop by Booth 414 and meet Jon Bouchard, a senior CFD engineer and Florida resident. With experience in 3D modeling for civil and environmental engineering, Jon specializes in applying CFD to solve complex water management challenges. Whether you're optimizing stormwater systems, enhancing wastewater treatment processes, or improving distribution and collection networks, Jon can show you how FLOW-3D HYDRO supports more effective decision-making and operational performance. 📅 Book a meeting and connect with Jon at the show: flow3d.com/fwrc-2025/ #flow3dhydro #fwrc2025 #cfd

How do beam shape and power distribution influence weld quality and process stability in high-speed e-mobility manufacturing? At EALA 2025, Marcin Serdeczny gave a presentation detailing how FLOW-3D WELD enables engineers to evaluate static and dynamic laser beam shaping strategies with a high level of precision. These simulations help answer key production questions—such as how to reduce spatter, improve melt pool stability, and maintain penetration depth—critical for battery module and lightweight structure welding. This work reflects the mission behind our FLOW-3D WELD 2025R1 release: ✔️ Achieve repeatable quality through predictive simulation ✔️ Advance innovations with support for complex beam shaping and multi-laser systems ✔️ Maximize production using faster HPC-enabled workflows ✔️ Streamline usability with a unified interface for efficient model setup and management 📽️ This video gives us a snippet of Marcin’s presentation. To learn more, message us through our FLOW-3D WELD page. #flow3dweld #cfd #welding

Poster abstracts for the FLOW-3D European Users Conference 2025 are being accepted through April 18th.  Join fellow engineers, researchers, and scientists from some of the region’s most renowned companies and institutions to present your work with FLOW-3D software. We are looking forward to presentations and posters from @Roche, @CranfieldUni , AWE, ETH Zurich, University of Innsbruck, Alfa Srl, BRLi, @edfenergy, JBA, Università degli Studi di Torino, and many others. Participate in shaping the future of CFD by sharing your knowledge, innovations, and success stories. Accepted poster authors receive a complimentary conference registration. 👉flow3d.com/call-for-abstr… #flow3d #EUC2025 #cfd

Attending RAPID + TCT and AeroDef? Come by booth 1225 to meet the FLOW-3D AM team and learn how simulation helps engineers in aerospace, automotive, and other industries explore new additive manufacturing technologies and accelerate time to market. We’re here through April 10—come say hello! #flow3dam #AdditiveManufacturing #RAPIDTCT #AeroDef

Excited to share that Garrett Clyma will be presenting at #AeroMat2025 on how FLOW-3D AM is accelerating material development in aerospace manufacturing. With supply chain constraints limiting material availability, model-based qualification offers a faster, more efficient path to material readiness. FLOW-3D AM provides insights into melt pool behavior, defect formation, and thermal gradients, reducing the need for costly trial runs. 👉Learn more about the ASM International AeroMat Conference and Expo: asminternational.org/aeromat-2025/?…

There's still time to register for our free webinar on April 10 at 12:00 PM ET. Join Brian Fox and Jon Bouchard as they share how FLOW-3D HYDRO is helping engineers tackle complex water infrastructure projects with confidence. 🎟️Let us know you’ll be there! us06web.zoom.us/webinar/regist…