QuesTek Innovations has introduced new simulation-driven capabilities in its ICMD materials design and engineering software platform to help accelerate additive manufacturing (AM) programs and maximize return on investment. By replacing costly trial-and-error with highly accurate simulations, ICMD reduces failed builds, speeds qualification timelines, and lowers overall development costs, delivering faster innovation where performance and safety matter most.

Predicting and Designing for Success

ICMD simulates key aspects of the printing process—melt pool dynamics, microstructure formation, and resulting part strength—so manufacturers can evaluate materials digitally before production. These validated predictions have been recognized in the U.S. Air Force Research Laboratory AM Modeling Challenge (2020) and the NIST AM Bench Challenge (2022), underscoring their accuracy and industry relevance.

In addition, the Alloy Design Toolkit enables the creation of materials specifically engineered for printability, helping avoid cracking and porosity. By ensuring that alloys are both high-performing and printable, manufacturers can accelerate the path to lighter aerospace components, safer energy systems, and advanced medical implants.

"Additive manufacturing is reshaping how critical industries design and deliver parts, but uncertainty has slowed adoption," said Bill Mahoney, COO of QuesTek Innovations. "ICMD lets engineers simulate outcomes before printing, cutting trial-and-error and helping companies bring safer, more reliable products to market faster."

Optimizing Builds with Printability Maps

Scaling AM requires precision in process parameters. ICMD addresses this challenge with intuitive printability maps that highlight safe operating windows for laser power, scan speed, and other variables. These maps help manufacturers reduce defects, achieve fully dense parts, and move to production with greater confidence and efficiency.

Accelerating Innovation Across Industries

From extending fatigue life in aerospace engines to enabling custom alloys for medical devices, ICMD provides a digital-first approach to materials innovation. These new AM capabilities allow companies to cut costs, reduce risk, and bring high-performance parts to market faster. The AM toolkit is the latest expansion of the ICMD software platform following the launch of a fatigue toolkit earlier this year.