AlphaSTAR’s family of tools include GENOA 3DP, an additive manufacturing simulation toolset aimed at accurately predicting the manufacturing anomalies associated with as-built AM parts. Advanced multi-scale progressive failure simulation methods are used to replicate the 3D printing process from material modeling/characterization to structural and thermal simulation in order to determine irregularities from micro to macro scale. GENOA 3DP enables users to optimize build processes to reduce weight, scrap rate and improve overall part performance to meet design specifications.