Engineering and manufacturing company Röchling Automotive was given an ambitious target by one of their automobile OEM customers: to reduce the weight of an engine by 35%. After partnering with Materialise to optimize, design, cast an aluminum inlet and print in plastic around the metal core, they are on their way to meeting this goal.
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.
By using Materialise OrthoView’s automated SmartHip wizard, planning time for surgeries has reduced by as much as 25%, according to Dr. Andrew Noble, a hip and knee specialist at Palm Beach Orthopaedic Institute in Florida.
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.
Born with Down syndrome and undergoing treatment for leukemia, Jalanea was diagnosed at 5 years old with Atlanto-axial instability – a dangerous point of weakness between spine and skull. Clinicians at Ochsner Hospital for Children used 3D anatomical modeling, generated by Materialise’s Mimics inPrint software, to help plan and successfully execute a complicated procedure that would ultimately save a brave little girl’s life.
A young patient with a painful deformity in his clavicle, which was causing him both cosmetic and functional issues, consulted Dr. Alexander Van Tongel. Dr. Van Tongel worked with Materialise clinical engineers for pre-operative 3D planning and 3D-printed surgical guides for a corrective osteotomy.
Digital pre-operative planning allows the surgeon to easily assess the size of components required, as well as other factors that the duration of the procedure. Having considered a variety of options in advance of the procedure, the surgeon was able to ensure both the equipment and his staff were prepared, thus saving valuable time in the OR.
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.
Treating a young patient born in 1993 who had an injury in 2009 with a malunion of the distal radius, Dr. Peter Axelsson from the Sahlgrenska Hospital in Sweden worked together with the Materialise Clinical Engineers for 3D-printed anatomical models, 3D analysis and planning, and 3D-printed patient-specific guides. This case was one of the first cases he did with Materialise.
Iristick’s smart safety glasses are at the cutting edge of design and electronic engineering. Working with Materialise, Achilles Design was able to get Iristick into small-series manufacturing at least 6 months ahead of schedule, reduce initial investment costs, and go to market with an agile offering tailorable to customer requirements.
Inspired by the design freedom that 3D Printing presents and armed with a creative concept unlike any other, leading designer Fabián Hofmann presented Materialise with a challenge. To partner with him in creating the industry’s first eyewear range with complex moving parts created entirely from additive technologies. With a re-imagined titanium ‘VOID’ hinge, a lightweight open core frame design, and an entirely new surface finish, ‘Cosmos’ was born.
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.