Manufacturers of high value components for critical service applications have used computer simulation to develop and optimize their processes for years. In the aerospace industry, turbine disks and blades are manufactured from exotic nickel and titanium alloys. Forging and heat treatment models have become an integral step in process development since the 1980's. Automotive and fastener manufacturers apply process models to their high volume components such as gears, crankshafts, pistons and a wide range of fasteners; many of which are subjected to critical and severe applications. DEFORM™ is an FEM system widely used in the above industries during the development cycle to reduce design iterations, troubleshoot problems and optimize processes.

In the medical industry, prosthetic devices such as knee and hip joints use similar exotic materials to aerospace components. The critical service nature of these components necessitates an optimum manufacturing process. Due to the cost, materials and service requirements, an increasing number of medical manufacturers are applying simulation during the product development cycle. This paper will provide an overview of current process simulation applications and future developments that are applicable to the medical manufacturing industry.