Stratasys and Novineer: FDM Parts That Perform Before You Print

The Problem with FDM Simulation

Traditional finite element analysis (FEA) treats 3D printed parts as homogeneous solids. That works fine for injection-molded parts. But FDM parts are not uniform — layer orientation, raster direction, infill patterns, and air gaps all affect how a part behaves under load.

Engineers know this. They compensate by over-designing, printing multiple test iterations, and relying on physical testing. The result: wasted material, delayed timelines, and parts that are heavier than necessary.

The Solution: Toolpath-Aware Simulation

Stratasys has partnered with Novineer to integrate NoviPath performance simulation directly into GrabCAD Print Pro. The key innovation: the simulation uses the same toolpath data that will be sent to the printer.

Instead of simulating a theoretical solid, Novineer models exactly what the printer will produce — layer by layer, raster by raster, infill pattern by infill pattern. Engineers can predict stiffness, strength, and failure locations before committing material.

Real Results from Early Users

The companies report that early users achieved up to 35% weight reduction on load-bearing parts while maintaining required performance margins. How? By simulating the actual printed structure rather than an idealized solid, engineers can optimize infill, orientation, and wall thickness with confidence.

The workflow runs entirely within GrabCAD Print Pro:

• Import your part and set up the print as normal
• Define load cases and safety factors
• Run the simulation to identify likely failure points
• Iterate on design or print settings virtually
• Print once, with confidence

Supported Materials and Systems

The initial release supports Stratasys FDM workhorses:

• F3300
• F900
• Fortus 450mc

Validated materials include Antero 800NA (PEKK), FDM Nylon 12CF, and ULTEM 9085 — the high-performance polymers used in aerospace, defense, and automotive applications where part failure is not an option.

Why This Matters

FDM has long been the workhorse of industrial additive manufacturing. But qualifying parts for safety-critical applications has been slow and expensive. This partnership addresses a fundamental bottleneck: the gap between what CAD says a part should do and what the printer actually produces.

By embedding simulation into the print preparation workflow, Stratasys and Novineer are moving FDM closer to true production readiness. Engineers can design lighter, stronger parts with predictable performance — and skip the weeks of physical testing that used to come standard with every new design.

The integration is available now through GrabCAD Print Pro.