Challenge

Create a highly detailed master (including 453 textured surfaces) for casting a shoe sole
 

Solution

Apply mass texturing instead of 1-by-1 texturing

Software used

Materialise 3-matic, Materialise Magics, Materialise e-Stage, Materialise Build Processor

Insight/How

Texturing, data preparation, automated support generation, slice-based technology

Industry

Shoe manufacturing industry (consumer goods)

insole

This shoe sole, 3D printed in Stereolithography by Materialise, provides shoe manufacturers with a detailed master for casting.

A 3D-Printed, Textured Master for Casting

Discover how four solutions from the Materialise software backbone give shoe manufacturers a shortcut to repair the worst file errors, texture hundreds of surfaces, automatically generate support and finally keep those huge data sets manageable.

Texturing: 80% Time Savings

Applying textures one by one demands massive amounts of time when you need to texture around 1,000 surfaces. With the texturing module of Materialise 3-matic, hundreds of surfaces that need the same type of texture can be grouped in surface sets and textured with one click. In this shoe sole 453 surfaces were nicely textured and aligned, saving at least 80% of time compared to 1-by-1 texturing.

mass texturing insole

Data preparation: Automatically Repair

To print the shoe in the most cost-efficient way, we created a hollow version of the model and added holes for resin drainage. In addition, Materialise Magics was used to position the shoe sole on the build platform in an optimal way.
 

data preparation

Automatic Support Generation: Save 20 min per Part

support generation

Manually generating support is a very labor-intensive job.  With automated support generation tool e-Stage, the support preparation time was significantly reduced. Using Materialise e-Stage can reduce data preparation time up to 20 minutes per part, depending on the complexity and size of the part. The support was not limited to the outside, but also supported certain hollow regions inside the shoe. Thanks to minimal contact points, the finishing time was reduced as well.

 

Slice-Based Data Processing: 5.8 MB Instead of 2 GIG

Slice based

Applying textures or structures to a model can easily result in very large STL files which become difficult to manipulate, store and transfer. Thanks to the slice-based  technology  of  the  Build  Processor,  the  demanding  triangle creating  to  an  intermediate  STL  file  was  skipped  and  the  desired  geometry  was  generated  directly  onto  the  slices,  avoiding  large  data. 453 surfaces where textured on a 5.8 MB size STL file, resulting in a slice stack of only 50 MB. Thanks to the slice-base technology an STL file of around 2 GB could be avoided.


 

The final result was this stunning textured master!

textured-shoe