Flow Science's latest release adds additive manufacturing, laser welding, and discrete element modeling to FLOW-3D.
Flow Science, Inc. has released FLOW-3D 2025R1 family of products, which now includes FLOW-3D AM and FLOW-3D WELD. This release includes several significant additions to FLOW-3D CFD simulation capabilities, which bring powerful functionality, full HPC support, and increased ease of use to all FLOW-3D users.
FLOW-3D AM 2025R1 enhances additive manufacturing simulation for material and technology development. This release introduces an integrated simulation platform for laser-based additive manufacturing processes like powder bed fusion and directed energy deposition, supporting engineers in creating advanced products. It features a unified user interface and pre-loaded process templates, streamlining the simulation setup and ensuring project continuity throughout the process.
Leveraging the core capabilities of the FLOW-3D solver, FLOW-3D AM 2025R1 now supports high-performance computing (HPC) platforms, improving simulation throughput. Additive manufacturing simulations on HPC platforms are up to approximately nine times faster compared to standard workstation configurations. This allows professionals to reduce time-to-market for AM applications by utilizing powerful computational resources for quicker simulation runtimes. With the dedicated FLOW-3D AM node available in FLOW-3D (x), engineers can benefit from an integrated ecosystem that enhances development cycles and supports design space exploration, sensitivity analyses, and process optimization with less manual effort.
FLOW-3D WELD 2025R1 delivers ease-of-use in precision welding simulation. This release introduces improved workflows with a unified user interface, simulation templates, new process automation and analysis capabilities, and significant performance improvements. FLOW-3D WELD’s brand-new user interface allows users to enable all the relevant physics models within a single application as well as define all required material properties for single or dissimilar metal welding applications. A new pre-loaded laser welding template makes simulation setup easier than ever. HPC compatibility brings unprecedented simulation speeds to laser welding simulations, while a dedicated FLOW-3D (x) node means faster time-to-market by enabling users to streamline model validation, identify process windows, conduct parameter studies, and optimize laser inputs and beam characteristics quickly and efficiently.
FLOW- 3D 2025R1 enhances particle modeling with the new discrete element method (DEM) model. This release extends particle-particle interaction capabilities for use cases such as granular material handling, slurry mixing, and particle-laden flows. HPC support reduces simulation runtimes, enabling rapid product development and process optimization.
FLOW-3D CAST 2025R1 empowers casting engineers to manufacture complex non-ferrous castings. This release includes improvements to the solidification and shrinkage, shot sleeve, and valve models. An improved solidification and shrinkage model with revised porosity outputs in the new EXODUS format allows users to simplify the analysis and interpretation of porosity. An enhanced valve model allows users to more accurately predict the final location of defects by specifying a target volume of metal allowed to exit valves and vents. In the FLOW-
3D CAST high-pressure die casting (HPDC) workspace, users can now capture the movement of solidified metal in the shot sleeve with the porosity-based solidification model, providing a much more accurate thermal profile during fill.
FLOW-3D HYDRO 2025R1 introduces a new discrete element method (DEM) model. This model allows users to account for particle-particle interactions such as collision and friction, providing utility beyond that of the standard Lagrangian particle model. The new DEM model provides insights into the stability of rocks or rip-rap in different flow conditions, opening exciting possibilities for cost savings and risk reduction for unique protection systems on riverbanks and other structures. The model can also help users gain insights into grit separation systems, stormwater separators, and other granular flow scenarios where small objects interact with each other.
For more information, visit flow3d.com.
