Digital twin–ready acceleration of production–scale wire laser additive manufacturing using NVIDIA omniverse

[GUT2060]

Hi Warp team,

I am excited to share our new work that leverages NVIDIA Warp for production-scale Wire Laser Additive Manufacturing simulation.

QH Build, LLC and CTU – Testbed Prague collaborated to advance WLAM toward an accelerated industrial manufacturing workflow.

Paper: Digital twin–ready acceleration of production–scale wire laser additive manufacturing using NVIDIA omniverse

Short description:
This work presents a digital twin-ready simulation framework for production-scale Wire Laser Additive Manufacturing that integrates multi-axis robotics with GPU-accelerated multiphysics modeling in NVIDIA Omniverse.

A major part of the framework was built on top of NVIDIA Warp, including:

High-fidelity laser–metal interaction modeling
Melt pool and solidification simulation using SPH
Thermomechanical distortion prediction using FEM
Robotics-aware multi-axis deposition simulation

We combined multi-axis robotic printing and high-fidelity multiphysics into a unified simulation platform built in NVIDIA Omniverse.

The framework was validated against physical builds and demonstrated on a production-scale part. The results show how simulation-driven parameter optimization can reduce cost and build time while supporting the transition from experimental WLAM setups to industrial manufacturing.

Here are some images and videos from our robotic setup and simulations:
YOUTUBE VIDEOS !