Cloud-based DigitalClone® solution will significantly reduce development time and cost for AM designs

May 29, 2020 (Buffalo, NY) – NASA has awarded Sentient Science a STTR Phase II contract for validation of DigitalClone ® physics-based modeling technology. DigitalClone not only predicts fatigue life performance of metal-
based additively manufactured (AM) components but also supports life-based comparisons of various design and process alternatives. The resulting multiscale models will enable NASA engineers to reduce iterations for design optimization by 75% and decrease cost for AM part qualification by up to 50%.
Key simulation outputs include fatigue life, part-level distortion, residual stress, grain structure, and porosity.

The Phase II program will enhance DigitalClone to provide a robust, validated digital twin AM modeling solution that links process parameters, microstructure, and fatigue life/performance. The solution is machine- and material-agnostic, meaning that it can be applied to a wide variety of AM processes and materials. Sentient will integrate advanced capabilities developed in the Phase I program with its proven and validated component life prediction (CLP) software, resulting in a commercial solution that will provide advanced physics-based AM modeling capability for both government and industry users.
Models developed in Phase I demonstrated extremely high simulation efficiency – with complete and accurate microstructure models generated in a matter of hours, much faster than other available AM modeling technologies.
The DigitalClone-AM software suite will be deployed on Amazon Web Service (AWS) cloud-based platform, enabling users to fully leverage the significant high-performance computing (HPC) resources offered in AWS.

“We are proud to partner with our friends at NASA in this ground-breaking program that will help unlock the enormous potential of additive manufacturing technologies. DigitalClone represents the culmination of years of government and private industry collaboration, and we are proud that it may play a part in enabling NASA’s future endeavors.”

Jason Rios, Vice President and General Manager of Aerospace for Sentient Science

Sentient Science Corporation is a Software as a Service provider of the cloud based DigitalClone® platform for the aerospace, defense, energy and transportation markets. The DigitalClone platform uses digital twins to enable industrial customers to represent the health risk of assets throughout the asset life-cycle from system design through to real-world field operations. These digital twins incorporating physics, material science and machine learning, allow capabilities such as detailed multi-body dynamics systems simulations under real-life operating conditions for fleet level analysis, as well as model-based predictions of current health for individual fielded assets.

Sentient Science has been recognized by the White House in 2014 with the Tibbetts Award, Bloomberg New Energy Finance Pioneers Award in 2016 and Frost & Sullivan with the New Product Innovation Award in Wind Prognostics in 2017.

DigitalClone has 3 Product Offerings:
DC-E DigitalClone for Engineering: DC-E is a multi-body dynamics simulation software that uses physics-based models to make fleet-level statistical life predictions of drive train components. It is the world’s only integrated solution from system modeling to bearing and gear detailed analysis to simulation-based component life prediction. No other solution incorporates microstructure-based life predictions.

DC-OM DigitalClone for Wind Operations & Maintenance: DC-OM is a cloud-based SaaS offering that provides model-based predictions of current health for individual wind turbines based on asset configuration, operational data and ambient conditions. Current prediction capability includes gearboxes and main bearings across a variety of OEMs.

DC-RM DigitalClone for Rail Operations & Maintenance:DC-RM is a new product category of “Precise Maintenance” tools to enable railroads to determine their best rail depreciation and maintenance scenarios, including grinding, rail profiling, load allocation etc. DC-RM life extension simulator enables railroads to make data-based budgeting decisions.

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