How Materialise Software Solutions Helped to Create the World’s Largest Jet Engine

The GE9X, the largest jet engine in the world developed for Boeing’s next-generation 777X jets, took its maiden flight on the GE flying testbed in March 2018. Discover how its crucial 3D-printed turbine parts were created using Materialise software solutions, and how these same solutions can power certified series manufacturing in Industry 4.0.

94% Lighter, 50% Cheaper, and More Performant – Optimizing a Suction Gripper Design for Metal 3D Printing

Solutions: Magics, Metal Production

Production tools are one of the applications where additive manufacturing truly shines. By optimizing the design of this suction gripper for 3D printing, Materialise reduced the manufacturing costs per gripper by half.

Digital, Interconnected, and Automated: 3D Printer Control for Industry 4.0

Solutions: Magics 3D Print Suite, Streamics

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.

TAILORED FITS Goes Off Piste in Ski Boot Design

Solutions: FDM

Until now skiers had to make a choice between ski boots that were either comfortable or high performing. TAILORED FITS founder Reto Rindlisbacher wanted to change this by combining these two features into one pair of boots. And he was able to do so thanks to mass customization made possible through 3D printing.

Lattice Structures Enable Optimized Tooling Design for Smoby Toys

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

Smoby, the number one toy manufacturer in France, makes merchandise featuring the Lightning McQueen car. Some of their toys are produced by IPC, a research center with significant expertise in 3D printing technology. To produce miniature versions of Lightning McQueen, IPC decided to print a metal mold that would perform better than ever before thanks to cooling channels that follow the exact shape of the car.

3D Printing Meets Prehistoric Preservation: Materialise Prints Life-Size Mammoth Skeleton

Solutions: 3-matic, Mammoth Stereolithography, RapidFit+, Stereolithography

When it comes to producing an exact replica of a mammoth, one thing is clear. Size matters. Recreating over 300 bones, some of which are over 2 meters in length (bigger than a fully grown adult!), is no small feat. Coupled with the need to avoid any invasive or potentially damaging work on the original bones, this project presented a unique challenge.

Materialise Software and GE Sensing Technology Push the Qualification of AM

Solutions: Magics

Without a fast, high-quality and automated AM process, companies can’t scale up production successfully. This qualification process should be as cost-effective as possible, meaning that the Non-Destructive Testing (NDT) costs of AM should be as low as possible. But how can you ensure consistency and repeatability throughout the entire manufacturing process? It’s all about machine learning, or leveraging large amounts of data to deeply understand the hardware.

Nissan Automated Their Production Process with Materialise Software

Solutions: Laser Sintering, Magics

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.

Hyundai Motors Improves Production Efficiency with Automation Software

Solutions: e-stage, Streamics

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?

Smoothing the Flow: How Sambon Saves 3 Hours on Data Prep per File

Solutions: Magics, STL

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.

Midwest Prototyping Reduced the Weight of SLA Molds by 42% Using Honeycomb Structures

Solutions: Magics

The new honeycomb structure in Materialise Magics22  allows companies to reduce material usage and printing time. As a beta tester of Materialise Magics22Midwest Prototyping was one of the very first to try out the new feature.

Volum-e Reduces Metal Support Removal by 50% Using Materialise e-Stage

Solutions: Aluminium, e-stage, Metal 3D Printing

Automation, speed, quality and cost reduction are all important drivers for improving the 3D printing process. Discover how volum-e increased their efficiency of their highly complex metal production.