M.Tec Engineering GmbH will showcase a simulation-based engineering approach for the additive manufacturing of thermoplastic components at Formnext 2025. The method is designed to move 3D printing from trial and error to a plannable process by virtually validating key risks, including dimensional accuracy, warpage and inter-layer bonding, before production. Virtual validation uses real material and process data to predict layer bond strength, distortion and structural mechanics. The company positions the approach for industrial deployment, where repeatability, cost control and shorter development cycles are priorities.
"The simulation-based method will accelerate processes and enable faster time-to-market. We only print what has been approved in advance - that is our credo. Simulation is the key to raising additive manufacturing to an industrial level," said Wolfgang Pelzer, Managing Director, M.Tec Engineering GmbH.
Reported advantages include:
- Higher functional reliability through early fault detection
- Shorter development times due to fewer prototype iterations
- Cost efficiency through reduced scrap and optimized material use
Method validation and production setup
The method underwent large-scale practical validation on a large-format automotive centre console. A FEM simulation, focusing on the time-dependent temperature distribution that drives layer adhesion and warpage, was used to predict component behavior. Thermographic measurements on the produced part closely matched the simulation results, indicating high predictive accuracy.
To support development with direct manufacturing feedback, M.Tec operates a large-format system, SpaceA-S-2000-500 from Yizumi Germany GmbH, at its site in Herzogenrath. This coupling of simulation and in-house production is intended to streamline iteration and scale-up. In addition, Akro-Plastic GmbH supplies tailor-made material solutions, with characteristic values fed directly into the simulation models to reflect processing reality.
Application scope and Formnext 2025 presence
According to the company, the development lays the groundwork for a digitized process chain from design to quality assurance. In this setup, additive manufacturing can serve as an economical alternative to injection moulding, particularly for functional components in small and medium series and for regulated applications. At Formnext 2025, visitors can discuss use cases with M.Tec specialists and review application examples at partner stands: Yizumi Germany, Hall 12.1 B131, and Akro-Plastic, Hall 12.1 A123. Individual appointments for non-binding consultations can be arranged via the M.Tec website.
