Materialise e-Stage for Metal

Materialise e-Stage for Metal is software that automates the support generation process for metal parts. This automation allows you to reduce costs, especially those related to man hours. The powerful algorithm reduces data preparation time for metal builds by up to 90% and finishing time by up to 50%. You can tweak the algorithm in the extensive parameter list to optimize it for your machine, material and part geometry, ensuring that all of your builds are created successfully. The support structure design allows you to remove nearly 100% of the powder from the support structure.

Save time on data preparation

There’s no need to spend large parts of your time on editing metal supports. With this fully automated software for Metal 3D Printing, you can save up to 90% of the time spent on support design.

Reduce the risk of build crashes

Since the support generated by e-Stage is created automatically, human errors are excluded. Every surface that should be supported will be supported.

The software also takes into account the force of the recoater (‘horizontal top load’ parameter) in order to prevent crashes caused by the recoater. In addition, it will reinforce the support connections of tall, thin parts to ensure a proper stabilization and prevent deformations while building. You can change the size of these connections in the parameter sets (‘horizontal connection height’ parameter).

Decrease powder consumption

Due to the open structure of the supports, nearly every powder particle that was not sintered during the build can be recovered in the build chamber. This increases the powder recovery rate by up to 20%. By using gusset parameters, you can force part-to-part connections in order to lower the powder consumption even more.

Decrease build time

With Materialise e-Stage, you can place parts directly onto the platform, resulting in a faster build time. Afterwards, you can use a wire EDM to remove the parts from the build plate.

Increase the lifetime of your wire EDM

The open structure of e-Stage prevents powder from getting trapped. Since the wire EDM doesn’t get into contact with the powder, it wears less.

Save time on finishing the parts

With Materialise e-Stage, support structures are generated only where needed and even avoid contact with the part as much as possible to keep finishing work to a minimum. This leads to a 20% reduction in part finishing time.

Save time on support removal

To ensure that you can easily break off support, Materialise e-Stage generates needle-thin contact points. The flexible grid structure makes it possible to remove parts from the support structure without any tools, leading to a 50% reduction of support removal time. Support removal has never been so easy.

Maximize your build platform

Materialise e-Stage allows you to nest parts in the z-direction without touching part surfaces. You can generate one e-Stage file for all your parts, without taking into account the distance between the parts beforehand. One file per part is also possible. In that case, you can maximize your build space by limiting the width of the support structure with the ‘maximum offset around part’ parameter.

Improve operator working conditions

e-Stage’s open structure results in less trapped powder in the supports, and consequently less powder in the working area, decreasing risks related to the health and security (HSE) of the operators.

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