Unlock Precise 3D Metal Forming Simulations with DEFORM-3D

A flexible, finite-element-based platform for accurate material flow and thermal analysis across forging, rolling, extrusion, drawing, and more.

DEFORM-3D is an open, flexible finite-element-based process simulation system that analyzes 3D flow and thermal behavior in complex metal forming processes. It predicts material flow and temperature distribution for forging, machining, rolling, extrusion, drawing, cogging, and upsetting, enabling reliable virtual testing and reducing costly shop trials. The platform supports multiple deforming bodies, arbitrary contact, and user-defined routines, making it suitable for both industrial production and academic research.

Features & Benefits

• Accurate 3D FEM simulations of metal forming
• Broad process coverage: forging, rolling, extrusion, drawing, cogging, and more
• Coupled thermal-mechanical analysis for realistic results
• Support for multiple deforming bodies and complex contacts
• Open system architecture: user routines and custom variables
• Die stress analysis and process optimization
• Industry-proven, robust; used in both research and production

How it works

Step 1: Define geometry, material models, and boundary conditions

Step 2: Run coupled thermo-mechanical simulations

Step 3: Analyze material flow, temperature fields, and die stresses

Step 4: Validate with experimental data and refine

Technical Specs

• Supported processes: forging, machining, rolling, extrusion, heading, drawing, cogging, compaction, upsetting
• Modeling capabilities: multiple deforming bodies, complex contact, die stress analysis
• Material models: plasticity, thermal conduction, phase changes (if applicable)
• Outputs: material flow vectors, strain, stress, temperature fields, contact forces, die stresses
• Platforms: Windows/Linux (specify if relevant)
• File formats and integration: compatibility with common CAD/CAx workflows; user-defined variables and routines

Use Cases

• Automotive powertrain and drivetrain components
• Aerospace structural parts
• General metal forming research and development