Italian engineers use new simulation tool to save big time and money.
After decades of watching 3D printer technology move forward with bigger machines and fancier materials, the software might be catching up to the hardware.
Markforged has released a new simulation-driven technology integrated within its Eiger workflow. The simulation tool helps engineers develop designs that optimize for stiffness and strength before anything is printed. The Waltham, Mass. 3D printer company is betting that giving its customers better tools to understand the strength of 3D-printed components will help push its technology forward.

To highlight the abilities of the new simulation tool, Markforged published a case study featuring the Italian research and development company PUNCH Torino. The team used the new simulation features to build a camshaft-locking tool for prototype engine assembly. The new simulation locking tool took the development process from trial and error to one based on simulation-driven design, saving time, money and resources.
The Unique Requirements of PUNCH Torino
PUNCH Torino started in 2005 as a General Motors powertrain engineering center. It was then purchased in 2020 by the PUNCH group—giving it its current name. The company designs and develops engines and uses simulation processes like CFD, FEA and NVH to optimize its designs. The company’s physical laboratory also helps its customers tune and develop engines. Beyond working with OEMs to design, assemble and test engines, PUNCH Torino also sells engines through GM OEM Sales.
To ensure the proper production and assembly of PUNCH Torino’s engines, its engineers developed a camshaft-locking tool printed on the Markforged X7 machine using Onyx composite base material. Based on its testing and simulations, the company says the continuous fiber Onyx material of the part is comparable to the aluminum counterpart the team aimed to replace.
When these camshaft-locking tools break, assembly of the engines has to stop. A revised tool design must then be completed immediately; however, the printing of a new tool could take up to 18 hours. Because of the unpredictability of the strength of 3D-printed parts, sometimes three or four locking tools would need to be printed at the same time with different designs before the best fit for each specific engine is found.
The anisotropic nature of the plastic and fiber materials was already adding to the complexity of the 3D printing process. Even though Markforged has published design strategies for how the carbon fiber can be laid out in a part, they generally give engineers an idea of what to do rather than a direct path.
This was a process with high degrees of difficulty on an assembly made up of several expensive prototype components, so any production issues sent shockwaves through both the schedule and the budget. A more accurate way of designing these locking tools was needed.
The Benefits of Simulation
Using the Markforged simulation tool, engineers at PUNCH Torino designed parts according to a specific project’s requirements. By setting stiffness targets, determining the maximum allowed deflections or designating a safety factor, the software and engineers could find the critical areas of the locking tools.
PUNCH engineers estimate that they can now simulate and build one tool instead of running a trial-and-error set of ideas through the system. The fact that the design exploration is done in the software instead of in the physical realm means the process is more efficient, saving money, time and resources.
The benefits of using the simulation tool was immediate. Instead of needing to build, via trial and error, a set of similar tools and hoping to find the perfect fit and strength for an engine build, parts could now be tested in the software. As a result, the average number of tryout parts for one tool was reduced from eight to one. Development time for each project dropped from 3 or 4 weeks to just 1 week. And the overall material cost per locking tool shrank from € 1,400 ($1,484) to € 200 ($212).

These are tangible immediate benefits that can also ripple throughout a company. Making more money per project means that the expensive carbon fiber reinforced 3D printers will pay for themselves faster. The time that engineers save on each project is time that can be spent on the next project, allowing a company to take on more business without hiring more engineers or buying more printers. Using the simulation software on multiple projects can help the engineers and designers to adopt better practices and share their skills throughout development.
What Happens Next?
The engineers at PUNCH Torino were an excellent choice to beta test the new simulation-based Markforged software. These are technicians and engineers who are familiar with prototype engine builds and components. Anyone who performs at this level in their field probably has a lot of ideas about addressing the biggest bottlenecks in their job. These simulation tools gave the designers the ability to make those changes and take the gut feelings out of the process moving forward.
I haven’t found any 3D printing simulation tool comparable to what Markforged offers, but the technology is solid and I assume other companies will be bringing simulations like this to market soon. However, the rollout of this type of simulation might take two paths. Manufacturing and development companies that use top-tier 3D printing technology like carbon fiber reinforced filament and concrete printing are dealing with high-dollar machines and high-dollar materials. Integrating simulation tools that will save valuable machine time and premium filament is a no-brainer.
Engineers and hobbyists at the most basic use levels, on the other hand, might not need to use simulation to create new proof-of-concept or showcase parts. Paying an up-charge for software that can predict stiffer and stronger parts might not have an easy return on investment for these use cases. A 3D printer farm or makerspace filled with dozens of machines isn’t likely to immediately buy this new software either.
However, saving printing time and filament cost is always a move in the right direction. And using these tools will help the industry make better designers and engineers.