Aibuild rolls out GPU-powered simulation tool running 10,000x faster than current systems

What happened: Manufacturing software firm Aibuild released FETS, a finite element thermomechanical simulation platform for additive manufacturing. The tool claims to operate up to 10,000 times faster than existing market alternatives. NIAR, the National Institute for Aviation Research serving the US aerospace sector, validated the system.

Why it matters: The platform cuts simulation time from hours or days to minutes. Engineering teams can now assess thermal risk, predict distortion, and analyze residual stress before production begins. The speed reduction removes a major bottleneck in additive manufacturing workflows where failed builds cost thousands in material, machine time, and labour.

Industry context: The system works across multiple additive manufacturing methods including Directed Energy Deposition, Wire Arc Additive Manufacturing, Friction Stir Additive Manufacturing, Fused Granulate Fabrication, and Fused Filament Fabrication.

It handles both metal and thermoplastic materials. The tool provides six simulation outputs: thermal distribution, thermomechanical behaviour, distortion mapping, residual stress analysis, interlayer bonding assessment, and crack prediction.

Our take: GPU acceleration paired with CAM-agnostic integration removes both the speed and hardware barriers that kept simulation out of rapid iteration cycles. NIAR validation gives aerospace manufacturers the compliance signal needed easing adoption.