Home Program Materialise Innovation Forum - September 17 & 18, 2008

Program Materialise Innovation Forum - September 17 & 18, 2008

Program September 17

 

  Room 1 Room 2 Room 3
09h00 - 10h00 Registration & Coffee Registration & Coffee  Registration & Coffee 
10h00 - 10h30 Nico Foqué - Materialise    
10h30 - 11h15 Dave Flynn - Express Pattern    
11h15 - 12h00 Gold Sponsor Presentations   Gold Sponsor Presentations
12h00 - 12h15 Networking Coffee Break Networking Coffee Break Networking Coffee Break  
12h15 - 12h45 Andreas Alonso-Egerer - Adidas Iain Todd - AMRC with Boeing / University of Sheffield  Sylvain Genot - Tomo Adour
12h45 - 13h15 Saima Elahi - Entire Imaging Solutions Jonas Van Vaerenbergh - LayerWise  Marc Brughmans - LMS 
13h15 - 14h30 Networking Lunch & Sponsor Time  Networking Lunch & Sponsor Time Networking Lunch & Sponsor Time
14h30 - 15h00  Leonardo Peretti & Daria Tirone - ProTocuBe  Mario Fleurinck - Melotte  Angus Lock - Mira 
15h00 - 15h30  Software Solution for Structural Light Weight Stereolithography Parts Ryan Kircher - Medical Modeling  Koen Engelborghs - Materialise 
15h30 - 16h00  Networking Coffee Break Networking Coffee Break  Networking Coffee Break
16h00 - 16h30  Katrien Lenaerts - Materialise Richard Hague - Loughborough University  Andrzej Grzesiak - Fraunhofer Institute 
16h30 - 17h00  Magics e-RP demo   Mark Brennan - Huntsman 
17h00 - 17h15  Announcement Pyramid Award winners    
17h15 - 23h00  Evening Program & Dinner  Evening Program & Dinner   Evening Program & Dinner  

 

Program September 18

 

  Room 1 Room 2 Room 3
08h30 - 09h00 Registration & Coffee Registration & Coffee  Registration & Coffee 
09h00 - 09h30 Fried Vancraen - Materialise    
09h30 - 10h00 Jo Massoels - Materialise Evan Douglis - Pratt Institute Lieve Boeykens - Materialise
10h00 -10h30 Ajay Purohit - Tata Motors Xavier De Kestelier - Foster+Partners Dave Flynn - Express Pattern
10h30 - 10h45 Networking Coffee Break Networking Coffee Break  Networking Coffee Break 
10h45 - 11h15

Andreas Hamp - Daimler

Jeremy Ficca - Carnegie Mellon University Andrys Posthuma - BPO
11h15 - 11h45 Maurizio Romeo - ProtoCast Jake Cook - Sweet Onion Creations Augustin Niavas - EOS
11h45 - 12h15 Katrien Lenaerts - Materialise Naomi Kaempfer - Materialise .MGX Carlos Garcia Pando - Prodintec
12h15 - 13h45 Networking Lunch & Sponsor Time Networking Lunch & Sponsor Time  Networking Lunch & Sponsor Time 
13h45 - 14h15 Brian Bauman - DSM Somos
Jonathan Jaglom - Objet

Magics Software Training

Jeroen Mingneau - De Nayer Institute
14h15 - 14h45 Beat Dobler - Huntsman
Simon van de Crommert - 3D Systems

Magics Software Training

Christoph Widmer & Nik Schulz - Phonak
14h45 - 15h15 Lars Ryberg - Arcam
Tim Heller - Stratasys

3-matic Software Training

Ben Geebelen - Materialise SDS
15h15 - 15h30 Wrap-up    
15h30 - 15h45 Bus Ride to Materialise  Bus Ride to Materialise   Bus Ride to Materialise
15h45 - 19h00 Guided Tour & Reception Guided Tour & Reception  Guided Tour & Reception 

Presentation Titles & Abstracts

 

David Flynn - keynote speaker - Express Pattern - USA

 

  • From Ideas to Innovation: RP&M and the Value of Speed and Quality
  • As an RP&M service provider, Express Pattern, Inc. operates in the gap between our customer’s ideas and the realization of innovative products. Software solutions from Materialise are essential to our ability to give those ideas tangible form. This presentation will review the evolution of RP&M applications and of customer expectations. As new capabilities are demonstrated, more acceptance is achieved, leading to demands for even higher performance. The expanded scope of these applications requires greater efficiency in the processing of design data.



Nico Foqué - Materialise - Belgium

 

  •  15 years of Magics: Past, Present & Future



Andreas Alonso-Egerer - Adidas - Germany

 

  • Usage of Materialise Software within the Adidas Footwear Development
  • Following a short startup video, a company introduction regarding size and brands within the Adidas group is shown. The presentation will give the audience a brief overview of products, categories and the footwear development process at Adidas. As the footwear development process as well as the footwear engineering process are presented, the use of the Materialise Magics software to create i.e. rapid prototype parts at Adidas within these processes is also explained. Moreover with the help of rapid prototyping technologies, supported by the Materialise Magics software, it is noted that development times and visualization of new technologies and designs are reduced and help to get a quick and useful feedback in the early stage of footwear development. Because of the mold cost in footwear production as well as the difference in needed mold output, the future scope for the rapid prototyping technologies and supporting software (i.e. Materialise Magics software) in terms of rapid molding and rapid part creation will be covered shortly, which will finish the presentation leading into the questions and answers session.



Saima Elahi - Entire Imaging Solutions- Canada

 

  • The use of Rapid Prototyping for Architectural Design
  • Entire Imaging Solutions Inc. is a leading reprographic/digital imaging provider with over 40 years of experience in the industry and is continually striving to be a premier print provider.
    Entire Imaging Solutions Inc. has introduced a unique technology of architectural Rapid Prototyping to the “print” industry of Architects, Engineers and Contractors. For Entire Imaging Solutions Inc. this type of prototyping has been constantly re-iterated and further developed as more and more clients tend to enjoy the luxury of “Rapid” prototyping.
    By providing our clients with on time delivery and improved models each time Entire Imaging Solutions Inc. strives to bring their models to the best level yet. By using Magics software we have been extremely successful to produce these models in a timely manner as well as improve our design development and quality of work. Entire Imaging Solutions Inc. welcomes the opportunity to continually share and learn the many possibilities there are and will be by integrating Magics Software with Rapid Prototyping.



Leonardo Peretti & Daria Tirone - Protocube - Italy

 

  • Complex Architectural Scale Models: Workflow and Examples
  • ProTocuBe is a young Italian company that promotes the use of Rapid Prototyping Technologies especially in architecture and, in general, for design and exhibitions to create prototypes, scale models and maquettes. ProTocuBe not only offers RP services, but develops 3D modelling and engineering, obtaining high level personalized products with special regard to the quality of finishes and details. In our experience, obtaining from the customer a “good”, ready to be prototyped 3D model is something very rare. Most of the times, we have to re-process a 3D model or create it from scratch, especially when it comes to complex scale models. So we study a construction project, which consists of the representation scale, of the customer’s requirements and the different RP technologies used to make the different components. At the end of the process the physical assembly is a sort of simple 3D-puzzle. Our main purpose is to substitute the traditional handmade approach, in order to be faster and more efficient in preparing models. In order to do so we acquire a common base (the 3D file), also useful to provide renderings and videos to complete the presentation of a project. Some case-studies of how the Magics application supports these activities will be showed and explained.

 

Katrien Lenaerts - Materialise - Belgium

 

  • "State-of-the-art" Presentation of Materialise Solutions



Richard Hague - Loughborough University - UK

 

  • Maximising Design Potential through Rapid Manufacture
  • The advantages offered by Rapid Manufacturing over conventional manufacturing are considerable with some hailing the advent of RM as a new industrial revolution that will bring about a renaissance in manufacturing for high wage economies. However, the author contends that the processes themselves are simply the enabling technologies for the creation and delivery of new products designed and distributed in new ways and that it is in the area of design where the main benefits can be accrued. The removal of most design for manufacture & assembly (DFMA) considerations encountered in conventional manufacturing gives exceptional latitude for product design – both on an aesthetic and mechanical sense – and thus it is discussed that we are entering a new era of “Manufacture for Design” (MFD), rather than the conventional DFM. This presentation will further examine the overall design freedoms that can be exploited with RM and also detail the limitations of conventional CAD in relation to RM. New design tools that are being investigated at Loughborough University will be discussed to show the potential for RM in the areas of customisation, optimisation, smart textures and high performance textiles.



Iain Todd - AMRC with Boeing / University of Sheffield - UK

 

  • Metallic Structures
  • Additive manufacturing technologies as well as finding use in the rapid prototyping of engineering components are looking increasingly promising as rapid manufacturing methods. Until now, however, the development of the technology has focused on the production of the required component form on-demand and for the production of one-off or non-structural components this ability to generate Form-on-Demand (FOD) has proved highly effective. To move this technology on from one associated with rapid prototyping to one which can be used to form structurally critical components will also require that we can produce components which have both the desired form and suitable metal microstructures such that in – service behaviour can be guaranteed - we can term this combination of form and function Performance on Demand (POD).
    There has been significant research effort in the field of FOD and much of the published work in the open literature on direct metal deposition technologies deals with this aspect. In contrast, there are very few widely published papers dealing with the control of solidification microstructures.
    In this contribution the structural response of different classes of metallic materials will be reviewed briefly and the structures resulting from current processes presented and discussed. Finally means of manipulating material microstructures will be described and briefly discussed.



Jonas Van Vaerenbergh - Layerwise - Belgium

 

  • Innovations in Metal Rapid Manufacturing
  • Based on many years of experience and technology development, LayerWise offers its Metal Rapid Manufacturing services for the production of metal components for industrial and medical applications. Recent technology developments and the enlargement of the number of materials now allow the direct digital production of entirely functional components. By taking advantage of the possibilities of Rapid Manufacturing technology, very complex metal components can be manufactured that were even impossible to produce conventionally! Further advantages are the short lead times, the absence of tooling, function integration and an unprecedented production flexibility that makes metal Rapid Manufacturing a valuable tool for the production of unique components, customized products and small series. The presentation will discuss the latest developments of LayerWise in the Metal Rapid Manufacturing technology and its materials. This will be illustrated with industrial case studies.



Mario Fleurinck - Melotte - Belgium

 

  • Layered Manufacturing @ Melotte, Vertically Integrated Direct Digital Manufacturing Solutions
  • Since 2004, Melotte has been actively exploring the Near-to-Net-Shape Manufacturing Technologies.
    Direct Digital Manufacturing is part of the company’s strategic diversification and is considered an innovative complement to the existing high-precision production apparatus.
    From the start, Melotte has developed an international network; now the company already has some impressive product references.
    Melotte differentiates itself with its complete offer, as well as with NTNM technologies, which combine Selective Laser Melting, Direct Metal Deposition and Electron Beam Melting with high-end Component Finishing Technologies.
    Related supporting services such as reverse engineering and modelling, FEA, laser scanning, optical measurement and thermo-dynamic analyses complete the offer. Melotte has completed many Direct Digital Manufacturing projects and is considered as one of the most active companies in the Metal DDM market.
    The company also has specific expertise in the field of NTNM (Magnesium Moulding) and DDM production technologies in metals, their specialties including Titanium, Inconell, Cobalt Chrome, Ceramic materials, Tool steel and Aluminium. All this is aimed at an extremely diversified international market.

Ryan Kircher - Medical Modeling - USA

 

  • A Metallurgical Perspective On the Use of Rapid Manufactured Metals for the Medical Industry
  • Additive rapid manufacturing in metals unlocks several opportunities for unique applications in many sectors of the manufacturing world including the medical industry. To date the rapid prototyping and manufacturing industry have focused mostly on the appearance, accuracy, and durability of materials and resultant products. If rapid metal fabrication is to become a viable manufacturing alternative the emphasis must be placed on the functionality of components. Implantable metal devices must be able to withstand harsh environments while exhibiting specific mechanical properties and must maintain their functionality for a long service life. This presentation will introduce the metallurgical characteristic of metals that are most important to medical device engineers and will give specific examples of how the properties of rapid manufactured metals compare to conventional materials. Finally, obstacles and potential benefits related to the use of rapid metal fabrication for medical applications will be discussed.



Marc Brughmans - LMS - Belgium 

 

  • Application of Image Based Meshing Technology for Fast and Accurate NVH analysis of Automotive Components
  • This paper presents a number of applications that highlight the benefits of image based meshing technology in the vehicle development cycle.
    In the early vehicle development stage, when the designed car is benchmarked against competitor vehicles, the technology enables the build-up of CAE models of competitor car components without the need to access proprietary CAD models. CAE based simulations allow the designer to compare noise and vibration performances and to set targets at component level prior to the first CAD model.
    In a later development stage, when prototypes are built and CAE simulations are used to refine the design, the accuracy of the CAE models is essential. Specific dynamic tests are carried out on the prototype hardware to establish the quality of the simulation model. The cases presented in this paper will demonstrate that a highly accurate CAE model can be obtained from scanned images of the prototype in a fast way. Compared to the CAE model based on CAD drawings, a higher level of accuracy is obtained because deviations from the frozen CAD design have occurred in the production/manufacturing process. Corrections of CAD based CAE models with state-of-the art model updating techniques would be less efficient and offer no guarantee for success.



Sylvain Genot - Tomo Adour - France

 

  • Computed Tomography Data Remesh by 3-matic for Direct FEA Applications in Automotive Industry
  • Till the beginning of 2007, industrials who want to study complex part in a first way, and study them through complex Finite Element Analysis, need to use expensive reverse-engineering services to build CAD surfaces and solid.
    This situation imposed as well, a mesh preparation to build a qualitative mesh in order to use some codes as Fluent for example.
    By using CT for data digitizing, industrials could extract easily internal features of complex part (cylinder head for example), and get back data on their computers through a long way described above.
    As the customers askings were more and more oriented to FEA, a dedicated tool – 3-matic – has been created to save time and budget !

    Complex parts could now be remesh directly on 3D-CT data by managing the quality and the size of the elements, and injected directly in 3D remesher and codes.
    The time saved by this new state-of-the-art digital workflow is close to 60% !

    Materialise build also a new way of work for industry !



Angus Lock - Mira - UK

 

  • Advances in CAD Cleanup for CFD at MIRA Ltd

 

Koen Engelborghs - Materialise - Belgium

 

  • Towards a revolution in FEA/CFD mesh generation & design optimisation



Andrzej Grzesiak - Fraunhofer Institute - Germany

 

  • Design and Engineering for Additive Fabrication: Industrial Test Cases from the Automation and Medical Sector 
  • Due to the fast growing Rapid Manufacturing applications the most important question for the involved industry is the question of design and engineering. Engineers and Designers needed to learn how to use ‘new’ materials and processes in their products. Nowadays, the activities go strong into design and bionic approach for additive fabrication. Due to a successful collaboration between research and SMEs a variety of new test cases and applications have been already developed.

    As an example from the orthopaedic sector new laser sintered prosthesis could be presented on the biggest orthopaedic fair by Gottinger GmbH and won high interest of the branches. Other most promising applications have been in the automation and custom machine-engineering sector, with an increasing number of possibilities in this area. An example is a gripper mechanism from robomotion GmbH that is used for organising and packaging chocolates. It includes LS and PolyJet parts. Both of them have been designed by taking into account the CAE rules for additive fabrication.

 


Mark Brennan - Huntsman - Belgium

 

  • The Use of Discrete Geometry in Modelling Polyurethane Foams
  • Foams are two-phase systems in which gas cells are enclosed by either a liquid or solid. Most of the non-gaseous material is contained in a network of triangular channels called ‘Plateau borders’ with the gas phase contained in rounded polyhedra cells [1]. This morphology presents significant challenges to traditional CAD based geometry preparation for CFD and FEA simulation. It is not easy to represent foams with traditional CAD entities and it is also time-consuming to prepare these structures for CFD and FEA simulations.

    Ideal foams, such as the Kelvin and Weaire-Phelan foam structures [2], can be used to study the influence of cell morphology on bulk material properties of foam. 3-matic makes it feasible to prepare these geometries for simulation rapidly and also to look at a much wider variety of cell morphologies than was previously possible. Moving from traditional CAD techniques to 3-matic it is possible to cut geometry preparation from weeks to days.

    Using Mimics, polyurethane foam [3] structures obtained from X-ray tomography can be converted quickly to CFD and FEA models. Combining Mimics and 3-matic it is possible to optimise surface meshes making it easier to create volume meshes for simulation.

    The key elements of both processes will be presented and applied to studying wave propagation in polyurethane foam.

    References:
    [1] Weaire, D. and Hutzler, S. (1999). The Physics of Foam. Oxford: Oxford University Press.
    [2] Weaire, D. and Phelan R. “A counterexample to Kelvin's conjecture on minimal surfaces”, Philos. Mag. Lett. 69, 107, (1994).
    [3] Randall, D. and Lee S., eds. (2002). The Polyurethanes Handbook. London: Wiley.




Fried Vancraen - keynote speaker - Materialise - Belgium




Jo Massoels - Materialise - Belgium




Andreas Hamp - Daimler - Germany

 

  • Rapid Prototyping at Mercedes Benz




Maurizio Romeo - ProtoCast Srl - Italy

 

  • Creative Minds and Creative Use of Magics: Winning Couple for Production
  • New RP and RM technologies allow to build geometries, parts that weren’t buildable until a few years ago. They allow to build parts with definitive materials, in particular with metallic materials: NOT using a sintering process but real MELTING (99,9% full of density) so the built parts can fit any requirements for international norms (aerospace and biomedical).
    In the same way we use Magics to prepare RP and RM jobs. This way we can manage “new hard” features to create innovative shapes. In particular we can create and manage new net structures, new very thin structures, built on a 3D envelop. These structures have a wide array of names: “honeycomb structure” (named after the structure that bees use for their beehives); “diamond structure”; “net structure”; “lightweight structure”.
    Applying these thin structures on some products, just on production, we can realize a new product, which brings new capabilities, new performances to the old products.
    The domains that are benefitting most of these new features are biomedical and aerospace.

 


Ajay Purohit - Tata Motors - India

 

  • Innovative Use of Rapid Prototyping & Magics for Manufacturing of Craftsmanship Tools
  • Currently TML is the biggest OEM in automobile company in India. It is involved in Manufacture of passenger cars, commercial vehicles & innovative products like small car costing around 1 Lac ( $ 2500 ). Engineering Research center is department involved in the research, design development & validation of all vehicles manufactured by TML. Rapid prototyping is practiced in Engineering Research Center for last 6 years and that way it is pioneer in Indian Automobile in world. Rapid prototyping is used in innovative way to find quick and reliable physical parts in different areas of product development of automobiles.

    As part of Quality Maturation tool TML (like other OEM's) uses full scale cubing model (E cube) or nominal BIW for checking of different plastic parts like bumper, dashboard, pillar trim etc.
    This is a long lead activity about 6 – 8 months and there was need for partial cubing model at early stage of program to support design validation of long lead items like bumper, dashboard etc . Early feed back during this stage will save on the modification of the hard tools and also can support for the changing surrounding BIW panels. Normally E cube is built after finalization of the BIW panel data as it is built in costly aluminum material by machining where modifications are very difficult to carry out. For one of prestigious project in TML the partial cubing model was developed by using RP parts as form blocks and Alufix modular fixture as the base. This was done for three long lead items Front Bumper, Rear Bumper & Dashboard Assembly.

    Here Materalise Magics software was used extensively for converting this idea into the physical reality.

 

Katrien Lenaerts - Materialise - Belgium

 

  • Magics 13 Update



Evan Douglis - Pratt Institute School of Architects - USA

 

  • Digital Alchemy: Excitable Surfaces in an Era of Manufactured Nature



Jeremy Ficca - Carnegie Mellon University - USA

 

  • Thinking Through Making: Digital Prototyping and Fabrication in Architecture Curriculum
  • The recently implemented digital fabrication lab (dFAB) within the School of Architecture at Carnegie Mellon University acts a bridge between virtual and physical worlds, fostering a design workflow equally vested in physical production as virtual simulation. It is a vehicle for the use of advanced digitally driven design, prototyping and manufacturing equipment, establishing a context through which students are better equipped to probe the potential of pervasive digital design and manufacturing technologies. This talk addresses the increased utilization of digital fabrication technologies within architecture curricular, its relevance to emerging alternative models of practice and the pedagogical challenges and opportunities encountered through curricular integration at CMU. While rapid prototyping tools are leveraged in automotive, aerospace and product design to reinvigorate analog and digital design workflows, their use within the design phases of the discipline of architecture is quite limited and typically utilized for the production of final representation models. As a result the design feedback loop is often severed at the point of printing. Attention will be given to efforts to promote iterative workflows where analog and digital design and output coalesce to offer the potential for a more responsive and intuitive workflow.



Jake Cook - Sweet Onion Creations - USA

 

  • From Web to Model by Lunch
  • The idea of crowd sourcing hinges on the power of the many to collaborate and contribute to a common cause. When the tools for creating architectural designs are available for free, anyone from anywhere can join in and participate. Google SketchUp is providing such an opportunity for people around the world. With the integration of Google Earth, 3D Basecamp and Sketch Up it’s now possible to leverage this collective work and download entire cities to build out to scale using 3D printing technology. As famous landmarks and buildings are created, posted online, and voted upon, the quality of 3D files continues to improve. Jake Cook from Sweet Onion Creations will give a brief overview on projects such as building out Jacksonville, Florida USA at 1/1800th scale and building the Google SketchUp world headquarters model. Challenges, ideas, and tips will be discussed in a format that includes images and video of the process of using Magics to quickly go from the sometimes messy .skp file format to a completed .stl file. Further information, video, and case studies can be downloaded from the company’s website: www.SweetOnionCreations.com



Naomi Kaempfer - Materialise .MGX - Belgium




Xavier De Kestelier - Foster + Partners - UK

 

  • Beyond Representation: additive fabrication in an architectural context
  • Over the last 15 years, rapid prototyping has been an integral part of the design process in the car and aerospace industry. In the last couple of years, the architecture profession has started to use these techniques in its design process, and some architecture schools have begun experimenting with these technologies.
    Foster + Partners have been one of the first architecture practices to fully integrate rapid prototyping within its design process. The technology was initially seen as a sketch model making tool in the early stages of the design, in particular for projects with complicated geometries. It surpassed this purpose within a year and it is now seen an essential design tool for many projects and in for many project stages. The office’s rapid prototyping department now produces about 4000 models a year.
    Besides, or perhaps because of, rapid prototyping, architects have started to think on how to implement the concept of additive fabrication in the construction industry. A few research projects on large scale additive manufacturing are ongoing at various universities. The application of layered manufacturing of building components or whole buildings, will query our current design processes and standards and potentially radically change the construction industry.

 


David Flynn - Express Pattern - USA

 

  • Additive Manufacturing Presentation: "e-Solutions: Easing the Data Crush with e-Stage and e-RP"
  • Managing work flow in a high volume RP&M Service Bureau is a challenge. The process is simplified with e-Stage and e-RP from Materialise. This presentation will highlight efficiencies realized through the use of e-Stage for stereolithography support generation. Early experiences with e-RP will also be covered.



Augustin Niavas - EOS - Germany

 

  • E-Manufacturing for Advanced Tooling Applications: Leveraging Design for Cooling Channels
  • e-Manufacturing means the fast and cost-effective direct production from electronic data. One of the most
    interesting and important fields of application is the design for the advanced tooling parts, that is the integration
    of conformal cooling channels into tooling inserts. Aim is not only the reduction of cycle time in injection moulding but also the products quality improvement and consistency.
    Freedom of design by DMLS (Direct Metal Laser Sintering ) extends considerably the frontiers of the cooling or
    tempering possibilities in tooling. From the early steps in the design process, designers need to be supported
    when facing the problem of creating the cooling/tempering system. The requirements for software should
    develop itself in the three principal directions:
    - Availability of design libraries and guidelines assisting in “cooling for tooling”
    - Thermal behaviour simulation foreseeing warpage, form filling characteristics, cycle time and showing
    the impact of cooling
    - Optimizing cooling channels geometries in terms of impact on cycle time and product quality.

 


Ben Geebelen - Materialise - Belgium

 

  • How customisation of Materialise technology leads to dedicated RPM solutions
  • With RM gradually taking off, mass customization is becoming a realistic option for many applications. New manufacturing technologies, a better understanding of the available materials and the development of new materials allow the mass production of goods that meet individual consumers’ needs.

    However, in order to reach near mass-production efficiency, the design of such products also requires dedicated tools. As each product is a one-off, it needs to be individually designed. Very often the product to be designed has an organic shape, or is based on the shape of another physical object. Reverse engineering this shape for each separate product would be too labor intensive to deserve the epithet “mass”, thus ruling out traditional CAD applications and processes.

    This is where Materialise can help.

    With close to 2 decades of experience in developing software for additive manufacturing, Materialise has all the know-how to perform CAD-like design operations on any geometry without the need for reverse engineering. This know-how is not only reflected in the Materialise software products, such as Magics and 3-matic, helping hundreds of customers around the world. Materialise also offers custom-development services, to adapt those software products to individual customers’ needs, or develop new tailor-made software.

    Materialise will analyze your needs, and develop a fast and user-friendly solution to allow the mass design of your custom products.




Andrys Posthuma - BPO Nederland - The Netherlands

 

  • Reliable CAE of Layered Manufacturing - New Engineering Methods for New Materials
  • Rapid Manufacturing (RM) offers promising potential for Mass Customisation. Without the need for dedicated tools and moulds, customized parts can simply be 'printed'. RM technologies are developing fast. Although the mechanical properties of RM materials are still limited, the geometrical freedom offered by RM technologies is almost unlimited. Because the performance of a part is determined by the combination of shape and material, smart design and engineering offer interesting new possibilities for the application of RM. Unfortunately, detailed and reliable engineering of RM parts is complicated. This is mainly caused by the material properties, which are difficult to cope with. Until recently, the right tools were not available. BPO is developing new methods on reliable simulations of RM products.

    Rapid Manufacturing mostly is layered manufacturing, causing non-isotropic mechanical behaviour of the material and the product.
    Engineers are not used to this, common CAE software can hardly cope with it. BPO has extensive experience in FEA with plastics and uses this experience to create lighter and stronger products. Currently we are developing the tools and methods for reliable simulation of layered materials. The first results are promising. At the Materialise Innovation Forum we will present the first cases: FEA results of complex layered products verified by practical tests.



Christoph Widmer & Niklaus Schulz - Phonak - Switzerland




Lieve Boeykens - Materialise - Belgium

 



Carlos Garcia Pando - Prodintec - Spain

 

  • Why Did We Choose 3-matic? Examples of Re-design for Metal RM
  • Traditional product design and development relies on parametric CAD software, and works with fairly simple surfaces and geometries; on the other hand, 3D scanning produces massive triangle meshes that hardly ever can be easily treated as simple surfaces. Reverse engineering converts groups of triangles in simple mathematical surfaces, in a more or less unassisted way, and usually a human operator has to improve the quality of the result and make it usable for parametric design and integration, this being a time consuming task.
    Rapid Manufacturing (RM) only works with triangle meshes, so in the end, any parametric 3D CAD design has to be translated into an .stl file. But a redesign step is frequently needed before building requested parts since RM process restrictions are different from any other manufacturing technology. The most usual tasks are offsetting, scaling, extruding, or the addition of geometries that make milling post-processing steps easier. We also need to improve the mesh quality, correct topology errors, close gaps, trim surfaces, and create rounded transitions the designer forgot to do, etc.
    But not only are these tasks easy at stl level with 3-matic while very difficult if having to turn the stl back to 3D CAD. We found out that the ability to work with both 3D CAD data and complex triangle meshes in the same environment at the same time makes life much easier and keeps the best of both worlds. 3-matic allows the designer to implement “natural” surfaces and geometries onto “mathematical” CAD shapes, and also to apply geometrical characteristics to scanned surfaces and modify them in a geometrically speaking accurate way.




Jeroen Mingneau - De Nayer Institute - Belgium

 

  • Scanning, Forward Engineering and Rapid Prototyping of Car Exterior
  • The presentation describes a very special and suggestive example of optical three-dimensional (3D) scanning, forward engineering and rapid prototyping of the exterior of a sports car, a Chrysler Crossfire. The scanning was performed using an ATOS system from GOM. This is an optical white light scanning machine. Projected fringe patterns are observed with two cameras. 3D coordinates for each camera pixel are calculated and a polygon mesh of the object’s surface is generated. To process and change the scanned data the forward engineering software 3-matic from Materialise was used. In the final phase of the project a small copy of the car was produced using a Selective Laser Sintering machine from Materialise. The process apart from the importance of the application to a unique sports car, demonstrates the ease of application of the optical system for measuring and forward engineering of large surfaces, as automobile body press parts at full-size, with high accuracy and reduced processing time, for design and restyling applications. This presentation gives you, not only a beautiful overview of the workflow, but also a good example of the synergy between these three innovative techniques.

 


Brian Bauman - DSM Somos - USA

 



Simon van de Crommert - 3D Systems - The Netherlands

 



Lars Ryberg - Arcam - Sweden

 

  • Rapid Manufacturing of Implants, New Methods and Materials



Tim Heller - Stratasys - Germany