In large-format pellet extrusion, thermal behavior is one of the main drivers of print failures — warping, delamination, and inconsistent bonding often appear too late, after hours of machine time and material have already been spent.

With the Helio plugin inside AdaOne, we bring physics-based thermal simulation and tool path optimization directly into the robotic AM workflow.

No file exports. No external tools. One continuous process.

Within AdaOne, users can now:
→ Simulate thermal behavior directly on tool paths to identify risk zones before printing
→ Optimize tool path speeds based on thermal constraints (speed up safe zones, slow down critical areas)
→ Reduce thermal defects while improving cycle time and dimensional stability
→ Move from manual tuning to repeatable, physics-based process parameters

The result is a more controlled and predictable LFAM process — reducing trial-and-error and improving efficiency from the first iteration.

And everything stays inside a single environment: from tool path generation, to simulation, optimization, and export.