Universal
AM Process Selector
Not sure which AM process fits your part? Set material, geometry, quantity, and priorities — ranked, scored list of viable processes with hard exclusion reasons.
Open toolSingle-purpose calculators with formulas shown and sources cited. 14 included in the Member tier. Pro tier unlocks all 48.
Member tools
14 calculators · included with membership- LPBF
Volumetric Energy Density
Compute LPBF VED from power, scan speed, hatch, and layer thickness. Includes process windows for common alloys.
Open toolVED = P / (v · h · t)≈ 78 J/mm³ · Ti-6Al-4V window 50–110 - Universal
DfAM Design Rules Checklist
Aggressive / typical / conservative design windows per process — walls, holes, overhangs, supports, text. Type your design value to check it live.
Open toolwall ≥ wall_min(process, alloy)✓ 0.8 mm · LPBF Ti-6Al-4V typical window - Universal
AM Part Visualiser — AI Image Generator
Pick a material, process, and part type — get a photorealistic AI render in seconds. Free preview of additive.tools' AI capabilities. 1 render per day (free).
Open tool - Universal
Surface Roughness Estimator
Theoretical Ra and Rz from layer thickness and surface angle (staircase effect). Upward, downward, and vertical faces. LPBF, SLS, FDM, SLA, DED. Per Grimm et al.
Open toolRa = t · cos(θ) / 4≈ 7.5 µm · 30 µm layer, 45° face - Universal
Heat Treatment Advisor
Standard stress-relief, solution, and aging cycles for AM metals (Ti-6Al-4V, IN718, 17-4PH, AlSi10Mg, 316L, CuCrZr) per AMS, ASTM F3301, and AMS 5664.
Open toolstress-relief → solution → age650 °C / 4 h · Ti-6Al-4V stress-relief - FDM / FFF
FDM Extrusion Width & Wall Planner
Actual extrusion width from nozzle diameter, layer height, and flow rate multiplier. Wall perimeter count from nominal thickness. FFF/FDM design rule compliance check.
Open toolw = (π/4) · d_n² · flow / h_layer≈ 0.45 mm · 0.4 nozzle, 0.2 layer - Universal
Equivalent Carbon Content (Weldability)
IIW and Pcm carbon equivalent for AM and DED steels. Preheating temperature estimate per EN ISO 13916 and AWS D1.1. Printability / weld-crack risk flag.
Open toolCE = C + Mn/6 + (Cr+Mo+V)/5 + (Ni+Cu)/150.42 CE · 4340 steel · preheat 100 °C - Universal
NDT Method Selector
Select the right non-destructive testing method for your AM part. Inputs: material class, defect focus, geometry, production volume, and criticality. Ranked scorecard across CT, X-ray, UT, FPI, MPI, eddy current, and visual inspection with detection limits and standard references.
Open tool - DED
WAAM Wire Deposition Calculator
Deposition rate, bead geometry, and heat input for Wire Arc Additive Manufacturing. MIG-WAAM, TIG-WAAM, and CMT process variants. Inputs: wire diameter, wire feed speed, travel speed, voltage, current.
Open tool - Universal
AM Dimensional Accuracy Estimator
Expected dimensional deviation (mean bias ± 1σ) for XY and Z axes by process, material class, and geometry type. Based on aggregated published accuracy datasets. Answers: what tolerance can I realistically hold?
Open tool - Universal
AFM Cycle Planner
Estimate cycles, processing time, and Ra reduction curve for Abrasive Flow Machining of AM internal channels — first public AFM planning tool.
Open toolRa(n) = Ra_f + (Ra0−Ra_f) · e^(−k·n)≈ 22 cycles · Ra 15 → 1 µm · IN718 - Universal
Wire EDM Cut Estimator
Estimate cutting time, kerf, recast-layer depth, and surface finish for separating AM parts from build plates and cutting hardened AM metal.
Open toolt = (L · H) / rate · passes≈ 31 min · 120 mm cut · 25 mm Ti-6Al-4V - Universal
Electropolishing Time-to-Ra Estimator
Estimate wet-electropolishing time and material removal to reach a target Ra on AM stainless, titanium, cobalt-chrome, nickel, and aluminium parts.
Open toolRa(d) = Ra_f + (Ra₀−Ra_f)·e^(−d/λ)≈ 9 min · Ra 6 → 0.4 µm · 316L
- UniversalPro
Build Time Estimator
Per-process build time from part volume, layer count, and machine throughput. LPBF, SLS, FDM, SLA, DED, binder presets included.
Sign in to unlockt_build = N_layers · (t_recoat + V_layer / Q̇)≈ 22 h · 80×40×30 mm Ti-6Al-4V on M290 - UniversalPro
Cost-Per-Part Estimator
Machine hourly + material + labor + post-processing → unit cost with margin. Currency-agnostic.
Sign in to unlockC = (C_mach + C_mat + C_lab + C_post) · (1 + m)≈ €185 · 200 g Ti bracket, batch of 6 - UniversalPro
AM Lattice Structure Library
Visual reference for BCC, FCC, octet-truss, gyroid, and Schwartz-P lattices. Property cards at any relative density plus AI renders via Flux 1.1 Pro for design reviews and stakeholder presentations.
Sign in to unlock - UniversalPro
Part Design Iterator
Describe an AM part, generate a photorealistic AI render, refine the description, and compare up to 6 design variations side by side. Faster than CAD for early-stage concept exploration.
Sign in to unlock - UniversalPro
Part Sketch — AI 3D Generator
Describe your part in plain English → AI generates a 3D model → estimated mass pre-fills Cost-Per-Part and Build Time calculators. No CAD file needed.
Sign in to unlock - UniversalPro
TCO — Machine Hourly Rate
Total cost of ownership: derive the effective $/h machine rate from purchase, depreciation, maintenance, facility, consumables, and power. Includes utilization sensitivity.
Sign in to unlock$/h = (CapEx/yr + OpEx/yr) / (hours · util)≈ $48/h · EOS M290, 70% utilization - UniversalPro
Carbon Footprint Calculator
kgCO₂e per part across ecoinvent, IDEMAT, ICE, and GREET LCA databases × IEA, EPA eGRID, DEFRA, Ember grid factors. Cradle-to-gate, ISO 14067.
Sign in to unlockkgCO₂e = Σ (m_mat · EF_mat) + E · EF_grid≈ 12.4 kgCO₂e · 200 g Ti, EU grid - SLS / MJFPro
SLS / MJF Packing Density
Build-chamber utilisation, virgin powder consumption, refresh cost, and cost/part for SLS and MJF. EOS P396, HP MJF 5200/4200, Farsoon 403P presets.
Sign in to unlockρ_pack = V_parts / V_chamber≈ 11% · EOS P396, 60 nesting parts - SLA / DLPPro
Jacobs Cure Depth (SLA)
Compute SLA cure depth from Cd = Dp × ln(E₀/Ec). Resin presets and full working-curve sensitivity table.
Sign in to unlockCd = D_p · ln(E₀ / E_c)≈ 0.21 mm · standard resin, 30 mJ/cm² - LPBFPro
Support Volume Estimator
Estimate metal LPBF support volume, mass, and total cost from overhang area, angle, and infill density. Angle sensitivity table included.
Sign in to unlockV_sup = A_overhang · h_avg · ρ_infill≈ 14 cm³ · 35° overhang, 20 cm² area - UniversalPro
Lattice Relative Density
BCC, octet-truss, gyroid, Schwartz-P relative density and Gibson-Ashby stiffness/strength scaling. SA/V ratio for heat exchangers and scaffolds.
Sign in to unlockE*/E_s = C₁ · (ρ*/ρ_s)ⁿ (Gibson-Ashby)≈ 0.18 relative E · 30% gyroid - LPBFPro
Thermal Distortion Risk
Estimate residual stress and distortion risk index (σ/σ_y) for LPBF and DED builds. Mercelis-Kruth model with preheat sensitivity table.
Sign in to unlockσ_res = α · E · ΔT / (1 − ν)0.62 · σ/σ_y for Ti-6Al-4V, T₀ = 200 °C - UniversalPro
DfAM Orientation Advisor
Score all 6 build orientations against overhang, surface quality, accuracy, build time, and mechanical load direction. Works for LPBF, SLS, FDM, SLA, binder jet, DED.
Sign in to unlock - LPBFPro
Melt Pool Geometry (Rosenthal)
LPBF / DED melt pool depth, width, and cooling rate from the Rosenthal moving heat source solution. Absorptivity, thermal diffusivity, and solidification velocity.
Sign in to unlockT − T₀ = (η · P) / (2π · k · r) · e^… (Rosenthal)≈ 95 µm depth · Ti-6Al-4V, 280 W, 1200 mm/s - UniversalPro
Shrinkage Compensation
Per-axis scale factors for sintering (binder jet, MIM-AM) and resin cure (SLA/DLP) shrinkage. Inputs: green density, target density, material class.
Sign in to unlock - FDM / FFFPro
FDM Infill Weight & Cost
Pattern × density × material cost. Quick feasibility for FFF prints.
Sign in to unlock - UniversalPro
Powder Flowability Index
Hausner ratio, Carr compressibility index, and Jenike flow factor from apparent/tap density measurements. Pass/marginal/fail for LPBF, SLS, and DED feedstock.
Sign in to unlock - UniversalPro
HIP Cycle Designer
Recommended HIP temperature, pressure, and dwell time for AM metals per ASTM F3301, AMS 2801, and DEF STAN 02-835. Covers Ti alloys, Ni superalloys, steels.
Sign in to unlock - UniversalPro
Fatigue Life Estimator (Basquin)
S-N curve estimation for AM metals using the Basquin law. Accounts for surface roughness stress concentration (Kt from Ra), build direction anisotropy, and porosity factor.
Sign in to unlockσ_a = σ′_f · (2 N_f)^b (Basquin)≈ 1.2×10⁶ cycles · Ti-6Al-4V, σ_a = 400 MPa - UniversalPro
Conformal Cooling Channel Designer
AM-enabled conformal cooling for injection moulds — heat transfer coefficient, Nusselt number (Dittus-Boelter), pressure drop (Darcy-Weisbach), and cycle time reduction vs. straight-drilled.
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Make vs. Buy Decision Tool
Given annual quantity, part complexity, lead time, and capex threshold — score AM in-house vs. outsource vs. conventional manufacture. Break-even volume analysis.
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Material Substitution Advisor
Find printable alternatives when your preferred AM alloy is unavailable or unsuitable. Weighted scoring across strength, ductility, cost, temperature, and processability.
Sign in to unlock - LPBFPro
Laser Parameter Optimizer
Derive LPBF process parameters from target VED and melt-pool stability constraints. Power–speed–hatch–layer sensitivity matrix with keyholing and balling risk zones.
Sign in to unlock - UniversalPro
Tolerance Stack-Up Calculator
Worst-case and RSS tolerance stack-up for AM assemblies. Accounts for build shrinkage, warpage, and post-machining allowances. GD&T-aware with AM-specific bias offsets.
Sign in to unlock - UniversalPro
Post-Processing Time Estimator
Bottom-up cycle time for AM post-processing: stress relief, plate removal, support removal, HIP, heat treatment, surface finishing, and inspection. Per-part and batch modes.
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Multi-Machine Build Cost Comparison
Compare build cost and throughput across up to 4 AM machines simultaneously. Same part, different machines — cost/part, time/part, and annual capacity at target utilisation.
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AM Defect Atlas
Visual reference for 8 common AM defects: lack-of-fusion, keyhole porosity, balling, delamination, warping, residual stress, surface roughness, and satellite particles. Root causes, fixes, and AI-generated microscopy-style renders.
Sign in to unlock - LPBFPro
LPBF Porosity Predictor
Predict lack-of-fusion and keyhole porosity from laser parameters. Maps VED and normalised enthalpy to relative density and flags dangerous regimes.
Sign in to unlock - UniversalPro
Powder Characterisation Tracker
Score a powder batch against key qualification metrics — particle size distribution, flowability, apparent/tap density, moisture, and oxygen content.
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Surface Treatment Selector
Rank post-print surface treatments (shot peening, electropolishing, tumbling, PVD, and more) against Ra target, material, fatigue criticality, and corrosion requirements.
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AM Microstructure Viewer
Expected microstructure for LPBF, EBM, SLS, FDM, and DED × common AM alloys and polymers. Grain morphology, phase content, grain size, and heat treatment requirements with AI microscopy renders.
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AM Process Comparison
Compare LPBF, EBM, SLS, FDM, DED, MJF, and Binder Jetting side-by-side: layer thickness, material families, surface roughness, cost drivers, and AI-generated part renders for each process.
Sign in to unlock - UniversalPro
AM Quote Sheet Builder
Generate a structured AM quote from part specs: process, material, volume, quantity, complexity, and post-processing. Material, machine, setup, and post-processing cost breakdown with PDF export.
Sign in to unlock - LPBFPro
Powder Reuse & Oxygen Pickup Tracker
Model oxygen content over powder reuse cycles, find the virgin-refresh ratio that holds within spec (ASTM F2924/F3001), and the cycles before powder goes out of spec.
Sign in to unlockO∞ = O_v + ((1−r)/r)·ΔOr ≥ 18% to hold Ti-6Al-4V < 2000 ppm
Process Library
Full reference 10 AM processes
Parameter envelopes, defect modes, and material compatibility — traceable to peer-reviewed sources.
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Powder Bed Fusion
(4)🧵
Material Extrusion
(1)🔦
Directed Energy Deposition
(2)💡
Vat Photopolymerisation
(2)🖨️