Repair a heavy STL file in order to create a mold


Various data preparation tools

Software used

Materialise Magics


Merge files, fix parts, orient them, cut them, etc.


Consumer goods

All Simpsons’ fans will remember the scene in The Simpsons Movie where Homer Simpson swings through the air on a wrecking ball and absorbs the shock with his potbelly. That’s impossible, isn’t it? Can Homer really stop a 5,000-pound wrecking ball from destroying a house? MythBusters saw it as their mission to find out!

MythBusters heroes, Adam Savage and Jamie Hyneman, tested this by making a replica of Homer Simpson’s body, from head to toe. Homer’s head has become an icon in itself, and is one of the most recognizable cartoon characters around the world. Therefore, the MythBusters team contacted Merrick Cheney from Mechinations to help them with this challenging task and make it look just like Homer does on TV. 



To make a full-size rubber replica of Homer’s head, you first need a mold. Merrick designed this mold using Materialise’s Magics software to put different files together, fix the design, orient it in the right way, cut it in different parts, and more.


“The great thing about Materialise Magics is that it can fix big STL files,” Merrick explains. “All tools in Materialise Magics were useful for making the mold. You can clean up your file to get watertight data that can be used for 3D Printing or send your fixed files to a CNC milling machine.”



The mold was cut into eight separate pieces and 3D machined. With this mold, the MythBusters team could go to the next step: casting Homer’s head in rubber. Once the rubber congealed, Adam and Jamie could make the rest of Homer’s body, fill it with water to add some weight and add the head on top. Our big yellow friend was then ready for some action!

Homer Simpson, swung through the air on a 5,000-pound wrecking ball and was smashed against the façade of a house. D’oh! And believe it or not, Homer’s big belly did make a difference. The impact of the wrecking ball on the house was much less when Homer is squeezed between the ball and the house. Don’t try this at home!

Do you think 3D printing software could improve your business, but you don’t know what option fits your business best? Our company is built on a great passion for 3D printing software. Let’s have a talk and see how we can render your business more efficient.

©Discovery Channel

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