Trusted by leading research institutions and industry partners
If you’re in manufacturing, you’ve probably experienced these headaches
Rejected Parts & Scrap
High scrap rates from failed builds (wasted material and time)
Costly Post-Processing
Up to 50% additional costs in heat treatment and rework
Machine Downtime
Frequent process tweaks and retries leading to idle machines
Production Delays
Missed deadlines due to trial-and-error and unpredictable quality
Inconsistent Quality
Variability in part performance, risking failures in service
Material Waste
Expensive powders and materials lost on non-conforming parts
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“Average scrap rate in aerospace additive can be 15-25% per build.”
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“One failed build can waste $10k+ in material and machine time.”
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"Catching defects can save up to 70% of production costs."
Every defective part means losing money – but it’s preventable.
What happens when heat imbalances go unchecked?
Without Thermal Intelligence
Simulation or trial-and-error
With OptiFab Thermal Intelligence
Pre- and in-process thermal control
Rejected part – requires costly repairs or scrapping
Defect-free part – ready for use immediately (No rework needed)
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Cracks, warping, and defects due to heat stress
- Unpredictable quality – trial & error approach
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Costly post-processing and wasted materials
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Predictive insights to prevent defects before they form
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Consistent quality every build – no trial & error
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50% lower costs – no expensive post-processing
Every build without OptiScan is costing you – in scrap, time, and opportunity. It’s time to stop the bleed.
OptiScan ensures your next build is a success, not an experiment.
OptiFab’s approach ensures your success in three steps:
Step 1: Prediction
Before production, we analyze part geometry, material properties, and process parameters to predict high-risk zones, like thermal hotspots, distortion-prone areas, or defect-prone features, so you can address issues before pressing start.
Together, these three steps guarantee first-pass success and defect-free production, fulfilling the promise of zero-defect manufacturing.
Step 2: Monitor
During production, our system continuously tracks key process signals (e.g., heat, energy input, scan pattern stability) in real time. This allows you to detect deviations early, prevent defect formation, and maintain process stability without trial-and-error.
Step 3: Outcome
After production, we generate a comprehensive digital quality record by analyzing production data against certification requirements. This traceability layer enables faster approvals, easier audits, and confidence in part integrity, without excessive re-testing.
OptiScan:
The First Smart Tool Unifying Design, Monitoring, and Certification
55%
Downtime Reduction
100%
Defect-Free Manufacturing
What manufacturers say about OptiFab
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What does OptiFab provide to manufacturers?OptiFab delivers advanced production recipes, real-time monitoring, and near-real-time control of manufacturing processes. We also ensure precise machine movement (toolpaths) for optimal results, minimizing defects and maximizing efficiency.
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How does OptiFab help reduce post-processing costs?Our technology eliminates the need for costly post-processing steps like heat treatment and HIPing. By ensuring the part is fully uniform during production, OptiFab saves both time and money while delivering high-quality, ready-to-use components.
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How does OptiFab reduce the need for testing and inspection?With our real-time monitoring and near-real-time control, the need for testing and inspection is almost entirely eliminated. Errors are detected and corrected during production, leading to defect-free parts and minimizing the need for post-production checks.
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What industries benefit the most from OptiFab’s solutions?Industries such as aerospace, automotive, and medical benefit significantly from OptiFab’s solutions. In these sectors, where high-quality, defect-free parts are critical and production efficiency is paramount, OptiFab helps deliver superior results.
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How does OptiFab control the manufacturing process?OptiFab controls machine movement through precise toolpaths, optimizing the manufacturing process in real-time. This ensures that each part is produced to exact specifications with minimal variation, reducing the need for rework and post-processing.
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Can OptiFab’s software be customized for my production line?Absolutely. Our software is highly customizable, adapting to your specific production environment, materials, and goals. Whether you need tailored porosity levels, surface roughness, or other adjustments, OptiFab ensures the best possible outcome for your operations.
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How does real-time monitoring and near-real-time control improve production?Real-time monitoring detects potential issues instantly, while near-real-time control allows our system to adjust parameters on the fly. This prevents defects from occurring, ensuring continuous, high-quality output with reduced downtime and minimal errors.
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What kind of cost savings can I expect by using OptiFab?By eliminating post-processing steps such as heat treatment and HIPing, and reducing the need for testing and inspection, OptiFab can save manufacturers significant costs and time, often up to 20% or more, depending on your production setup and scale.