Medical

Furthering Orthopaedic Research through Enhanced Remeshing

Solutions: FEA

A growing number of patients has undergone both a total hip and a total knee replacement in the same leg. Researchers at the Biomechanics section of the University of Leuven wanted to understand whether the distance between the hip and knee implants — the ‘interprosthetic gap’ — would influence the femoral strength. This required a robust workflow for creating accurate finite element models. Using the Materialise Mimics Innovation Suite allowed the researchers to generate accurate surface and volume meshes based on medical image data.

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Software

AM Simulation: A Guide to the Best Part Orientation and Support Configuration

Solutions: FEA, Magics, Magics 3D Print Suite, Metal 3D Printing

In this case study, we investigate different part-support configurations of a patient-specific CMF implant, and determine which configuration is most suitable for the AM process. We do this by simulating deformations via inherent strain method and comparing the final deformations of the parts after support removal. 

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Software

Tata Motors Improves the Efficiency of Their Prototype Production

Solutions: 3-matic, e-stage, Laser Sintering, Magics, Stereolithography

With over 9 million manufactured cars, buses, trucks and other vehicles, Tata Motors is leading the automotive industry in India. And by producing the majority of their output in their own country, they contribute to the ‘Make in India’ policy of the Indian government, launched to stimulate the country’s growth. As drivers of the Indian automotive landscape, they ventured to intensively apply 3D Printing as a new technology for their prototype development, using both Laser Sintering and Stereolithography machines. But how do they make sure they use these technologies in the most efficient way?

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Software

Predicting Deformations of Titanium Inserts: The Power of Simulation Software

Solutions: Magics

Sandwich panels are used in aeronautics and aerospace applications where high structural rigidity and low weight are required. Together with ATOS, a global leader in digital services, we have developed a lightweight titanium insert design for a sandwich panel. The insert design was specifically developed for production with Additive Manufacturing (AM) and allowed for a 66% weight reduction of the traditional insert design, which has a brick-like shape.

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Software

Smart Design, Smart Mobility: KLIO Contributes to South Korea’s Smart Mobility

Solutions: 3-matic, Build Processor, Laser Sintering, Lightweight Structures, Magics

Driving pleasure, ergonomics and safety have always been important for the automotive industry. A rising new trend is smart mobility. This means applying innovation and modern technology to stimulate sustainable mobility. One of the goals of smart mobility is to cope with the negative effects of mobility such as traffic jams, pollution and traffic casualties.

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Medical

Digitally Planning A Valgus Osteotomy For Femoral Neck Fracture Non-Union

Solutions: OrthoView

A 43 year-old female runner suffered a displaced right femoral neck stress fracture that failed to heal with conservative treatment. She was treated at an outside hospital with percutaneous reduction and internal fixation.

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Software

Texturing 453 Surfaces of a Shoe Sole: Discover Mass Texturing

Solutions: 3-matic, Build Processor, e-stage, Magics, Stereolithography

Shoe manufacturers often use a master to cast the soles of the shoe. Instead of creating a mold for each type of sole, the bigger shoe manufacturers nowadays 3D print the soles. Manually assigning a texture to each surface area takes a lot of time. In addition, you end up with huge STL file sizes that your computer can no longer handle.

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Manufacturing

Reimagining Agricultural Pest Control with Soleon’s 3D-Printed Drones

Solutions: Certified Additive Manufacturing, Laser Sintering

Italian drone company Soleon has diverse projects, from aerial photography to thermal mapping drones. For years now, Soleon has been working with Materialise to adapt their products quickly to the needs of their customers, shorten lead times and reduce the weight of the drone parts compared to expensive and time-consuming milled parts.

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Manufacturing

Philips’ Lightbulb Moment: 3D Printing Becomes Essential Production Thinking

Solutions: Additive Manufacturing, Metal 3D Printing

Working together Materialise and Philips Lighting explored the benefits 3D Printing could offer for components in a production environment. The first two parts we developed; a lamp holder bracket, previously prone to part failure and a redesigned suction gripper; are together realizing cost savings of around €89,000 a year.

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Software

The Spider Bracket: A Topology Optimization Project by Altair, Materialise and Renishaw

Solutions: 3-matic, Build Processor, Magics, Metal 3D Printing, Renishaw

Materialise worked together with Altair and Renishaw to create an R&D spider bracket. The amazing thing about this bracket is that it contains hybrid lattice structures and is successfully 3D printed in Titanium. This design could not have been created with conventional manufacturing methods.

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Software

A 63% Lighter Titanium Aerospace Part

Solutions: 3-matic, Lightweight Structures, Metal 3D Printing

With Materialise software that is perfectly compatible with simulation and analysis software, you can create strong and light industrial metal parts. This aerospace part was 3D printed in Titanium at our metal competence center in Bremen, with a 63% weight reduction compared to the traditionally manufactured part.

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Software

Unlimited Design Freedom and Short Lead Times for Titan’s Jewelry Business

Solutions: Magics, Magics 3D Print Suite

Jewelry lovers, especially in India, are familiar with the names Tanishq, Gold plus and Zoya. Three exclusive brands created by Titan Company Ltd, a company with decades of experience in manufacturing quartz watches and exquisite jewelry.

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