Introduction to Welding & Additive Manufacturing: AM Plug-in + Python/DFLUX
This is a hands-on, project-based course. We start simple and finish strong.
You’ll learn two ways to do AM and welding in Abaqus:
- No-code path: AM Modeler plug-in (setup, tricks, reliable results)
- Coding path: Python scripting + DFLUX (Fortran heat input) + USDFLD (phase change)
Bonus: 1-year access to our premium G-code translator (included with the course).
What you’ll be able to do
- Set up AM/welding models fast with the AM Modeler (layers, scan paths, hatch, supports).
- Do the same with Python + DFLUX when you need full control.
- Use USDFLD to capture phase change for SLM/LPBF.
- Measure melt pool width, depth, length, and volume.
- Model complex shapes (think propellers, implants) for WAAM and LPBF.
- Extract residual stresses and distortion you can trust.
Projects we’ll build (end-to-end)
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- Plate weld (GMAW) — moving heat source with DFLUX (clean, simple start).
- Pipe circumferential weld — full-round weld on a pipe; multi-pass strategy, stress results.
- Nozzle-to-vessel weld (with Python) — auto-create the weld path, steps, and post-processing.
- Propeller with WAAM — layer planning on a complex shape; supports and monitoring.
- SLM/LPBF “Complex scan patterns” — hatch strategy + USDFLD phase change
- Validation of the model with Ding’s Paper
Who this is for
Engineers, researchers, and students who want practical AM/welding simulations for real projects—without drowning in theory.
Format
- Comprehensive course: 4 weeks, 20 hours total
- Live demos + guided builds + Q&A
- Level: basic Abaqus helps; no subroutine experience needed
Tools & setup (simple)
- Abaqus 2014+
- Fortran compiler (e.g., Intel oneAPI) for user subroutines
- A laptop/PC that can run medium FE models
You’ll take home
- All Python scripts, DFLUX and USDFLD templates
- Ready-to-run input files for every project
- A step-by-step checklist for AM & welding runs
- 1-year premium G-code translator access
- Certificate of completion
Instructor
Saman Hosseini — 7+ years in FEM; delivered many AM and welding simulations for academic and industrial teams.
Enroll now, limited seats.
Learn the AM plug-in, master the coding route, and leave ready to model any complex geometry with confidence.
