Nissan uses 3D printing technology to create prototypes and experiment with new vehicle shapes. This involved a lot of manual work. Thanks to Materialise software, they managed to change the entire process and make it much more efficient. Data preparation time was reduced from months to seconds.
By relying on 3D Printing, Hyundai Motor Company can create new products in a fast and cost-effective way, and experiment with designs with almost no design limitations or material waste. But how do they efficiently manage their Additive Manufacturing (AM) production?
When it comes to retrofitting for aircraft, time is of the essence. During cabin retrofits, the integration of newly designed elements might create a need for adapting or redesigning some panels or spacers, which are typically required in low volumes and short timeframes. With tight retrofit timescales to meet, Airbus was looking for a quick and smart solution to produce these spacer panels, and they found it in Materialise’s Certified Additive Manufacturing.
Employing robots to conduct equipment inspections is a longstanding focus for Shell – one with potentially huge safety and efficiency benefits. To avoid transporting its large and valuable robots to promotional events, Shell asked Materialise to create smaller models to serve as demonstrators. Through a bespoke combination of 3D Printing technologies, materials and finishing techniques, Materialise produced two precise replicas that look exactly like the original machines.
A 60 year old lady was suffering from shoulder pain and limited range of motion. Analysis of the medical images indicated a devastating shoulder arthrosis with severe medialization and erosion of the glenoid. Due to a complete loss of the glenoid vault, implantation of a classic pegged baseplate for reverse total shoulder was not an option. In addition, interposition of a massive bone graft would have little chance for ingrowth and survival, hence little chance to offer sufficient stability.
At the age of 81, the patient was suffering from a Paprosky type 3B defect and already underwent hip revision surgeries prior to seeking the help of Mr. Dunlop. He is not alone, because data from joint registries show that 27% of the revisions is not an initial one and those re-revisions have a 3 times higher chance of failure compared to initial revisions.
Total hip replacement is widely considered a very successful surgery to relieve pain and restore mobility to patients. Since the shape of every patient's femur is different, the femoral offset, anteversion angle and length can vary widely between patients. Therefore, to achieve good functional results, an accurate restoration of hip biomechanics with appropriate implant and sizing options is essential.
In total hip replacement surgery, short hip stems are presumed to reduce proximal stress shielding compared to traditional, long stems. Belgian researchers virtually implanted a commercially available calcar-guided short stem in a series of bones with deviating proximal geometry and performed finite element analyses. Given the large number of FEA models that had to be created, they used an automated methodology.
Patellofemoral joint complication is among the leading causes for the failure of primary total knee replacement. When the joint wears down and a total knee replacement surgery is recommended, one of the goals of the femoral component is to restore the trochlear groove in such a way that the patella follows its natural pathway during knee movement. Exactech performed a study to understand the native, healthy trochlear groove.
Sambon Precision & Electronics manufactures audio devices (earphones, headphones and speakers) and keypads for distribution in South Korea and oversea. When developing a new product, producing a prototype is a mandatory step in the development process. Sambon 3D prints the prototypes since it’s a fast and flexible method. Unfortunately, their 3D printing workflow wasn’t that smooth, and took up a lot of time for the data preparation team. Using Materialise Magics software, they were able to reduce file repair and platform preparation time significantly.
The new honeycomb structure in Materialise Magics22 allows companies to reduce material usage and printing time. As a beta tester of Materialise Magics22, Midwest Prototyping was one of the very first to try out the new feature.