Since it opened in April 2016, Materialise’s production site for metal 3D printing in Bremen has expanded to include more new 3D metal printers. Materialise Streamics software ensures optimum, cost-saving management of the printers and the orders completed with them. Process engineer Philip Buchholz explains how Streamics has been modified to meet requirements from a growing pool of printers to diverse customer needs.
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.
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.
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.
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.
328 handles the maintenance, modification and refurbishment of the Do328 fleet. In preparation to re-launch serial production of this aircraft, 328 works with Materialise to make plastic spare parts lighter, cheaper, and faster to produce.
Each kilogram put into orbit costs around $20,000. Every gram saved helps make space a more attainable frontier. So Materialise worked together with the engineering division of Atos, a global leader in digital services, to reinvent a titanium insert that is widely used in satellites.
Fokker Elmo specializes in solutions to keep the immense wiring of an aircraft clear and manageable before and during installation. With clever 3D-printed assembly tools, Fokker Elmo keeps its production routing process organized, even when handling hundreds of meters of wiring.
Trimble UAS, formerly known as Gatewing, started working with Materialise back when they were designing the surveying and mapping drone Gatewing X100. Four years later, the prototyping partnership has evolved into an ongoing certified additive manufacturing project.
Streamics and Magics, two of our leading software packages, support Avio Aero in manufacturing lightweight titanium blades for jet engine turbines: from preparing builds for the different Additive Manufacturing machines, to offering the necessary automation, control and traceability required to produce regulated aviation parts.
Solutions: 3-matic, Additive Manufacturing, CAD, Magics, Metal 3D Printing
A Delft University graduate student wanted to use topology optimization to minimize the volume and weight of an aircraft engine bracket. However, it was taking too long to convert optimized files back to a CAD format: until he tried 3-maticSTL.
In order to produce the X100, Gatewing uses a combination of manufacturing processes, and for parts that need the extra advantages provided by Additive Manufacturing and Vacuum Casting, they come to Materialise.