Innovations in Software for Rapid PrototypingKarel Brans

Seminário de Tecnologias2012

Karel BransBusiness Development Manager – Software for Additive Manufacturing

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Content

• Introduction to Materialise

• Overview Software Solutions for Industrial RP

applications + Examples

• Engineering and Design on STL: 3-matic

• Lightweight and Topology optimization• Lightweight and Topology optimization

• Texturing: Solution for applying textures on complex surfaces

• Data preparation with Magics: Magics

• Fixing, cutting, structures, ...

• Sintermodule: 3D Nesting for Selective Laser Sintering

• FormFit: Solution for shipping parts

• e-Stage: Automatic Support Generation for Stereolithography

• Conclusion

Introduction to Materialise:

• Started in 1990

• Currently over 800 employees worldwide

• HQ in Belgium, offices all around the world

• Technology company

• Active in the field of Additive Manufacturing...• Active in the field of Additive Manufacturing...

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Introduction to Materialise: Materialise Global Presence

Japan

Ukraine

Turkey

Taiwan

China

USA

SingaporeMalaysia

TaiwanHong Kong

Australia

Offices AgentsProduction Unit

Czech Republic

GermanyAustria

Italy

Spain

France

Portugal

Belgium

United Kingdom

Introduction to Materialise: 3 Core Competences

Additive Manufacturing

Additive Manufacturing

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Medical Image Based

Engineering and Manufacturing

Medical Image Based

Engineering and Manufacturing

Digital CADDigital CAD

Introduction to Materialise: 3 Core Competences

Additive Manufacturing

• Layer by layer production of parts(3D Printing)

• No need for tools, only 3D design required

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• Very few limitations in part complexity

• Broad range of technologies

• 315.000 parts printed in 2011

• Machine park of 80+ machines

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Introduction to Materialise: 3 Core Competences

Digital CAD2

• Represent 3D volume by triangles

• Design automation

Introduction to Materialise: 3 Core Competences

Medical Image Based Engineering and Manufacturing3

From CT/MR images

…to anatomical engineering...to physical models

Introduction to Materialise: 3 Core Competences

Additive Manufacturing

Additive Manufacturing

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Medical Image Based

Engineering and Manufacturing

Medical Image Based

Engineering and Manufacturing

Digital CADDigital CAD

Introduction to Materialise: 3 core competences in 8 focused business units

SAMSoftware for AM

.MGX

AMS

RapidFit+

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PRODUCTIONPRODUCTION

SOFTWARESOFTWARE

i.materialise

.MGX RapidFit+

Orthopaedics

Biomedical

Cranio-maxillofacial

SERVICESSERVICES

Introduction to Materialise: Software for Additive Manufacturing

SAMSoftware for AM

.MGX

AMS

RapidFit+

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PRODUCTIONPRODUCTION

SOFTWARESOFTWARE

i.materialise

.MGX RapidFit+

Orthopaedics

Biomedical

Cranio-maxillofacial

SERVICESSERVICES

Overview Software Solutions for Industrial RP applications

FEA, windtunnels, engineering, ...

2D to 3D Data

Engineering & design

AM/RP preparation

ProductionQuality control

Post processing &

shipping

Mimics 3-maticMagics

e-Stage

Build processor

Mimics

3-matic

Formfit & Rapidfit+e-Stage processor 3-matic Rapidfit+

+

+

12Streamics

Engineering & design on STL

Lightweight technologies

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Scaled models (wind tunnel)wall thickness adjustements, design fixtures, add ribs for clay...

Texturingaesthetic and functional textures

Engineering & design on STL: Topology Optimisation

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Engineering & design on STL: Topology Optimisation

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Engineering & design on STL:3D Texturing

Create texture on STL data:

� Decide where to apply the texture

� Use a bitmap with a 2D texture

� Automatically convert to a 3D texture

Engineering & design on STL:3D Texturing

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AM preparation with Magics

Import filesFix and

prepare files

Enhance and

edit data

Prepare the

platform

Print better

parts

Import nearly all

file formats and

native color

information

Create waterthight

data

Correct problems

Create short-cuts

to suit your workflow

in a user-friendly

interface

Add logos, series

numbers, etc

Apply textures

Perform boolean

operations

Hollow parts

Perform cuts, ...

Duplicate parts

Orient parts

Define no-build

zones

View slices

Detect collisions

Save platforms

Generate reports

Magics AutoFab Suite is the ideal solution for professional

users of additive metal melting processes.

AM preparation with Magics

• Examples:

• Fixing

• Cutting

• Structures

• Sintermodule

• FormFit

• Trapped Volumes

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AM preparation with Magics:Magics Sintermodule

Save money by optimizing your builds

� Lower your powder consumption and production costs

� Save money by reducing data preparation time

� Increase nest density and pack more parts in same build enveloppe

AM preparation with Magics:Magics Sintermodule - Powder Savings

Powder savings based on nest density increase from 6% to 7%

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Nest density 6%

Height 148 mm

Nest density 7%

Height 126 mm

AM preparation with Magics:Magics Sintermodule - Powder Savings

AM preparation with Magics:Magics FormFit: Solution for shipping parts

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e-Stage: Automatic Support Generation for Stereolithography

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what: single button solution forintelligent & automated support generation

aim: optimize support for your application

e-Stage: What is e-Stage?

Which benefits does e-Stage bring to you?

• e-Stage reduces lead time and improves quality in

several steps of the process

1. Minimize Lead Time and Cost:

• Very strong reduction of support design

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• Very strong reduction of support design

time

• Saving resin and build time

• Strong reduction of support removal time

2. Reliable Quality:

• Support generation is repeatable and

traceable

• Less build failures and improved part

quality

• Minimal surface contact preserves

surface integrity

Impact of e-Stage at Materialise and customers

• At Materialise about 99% of SLA parts are made

with e-Stage supports!

• e-Stage works with annual licenses

• Until now, ALL customers have renewed the licenses • Until now, ALL customers have renewed the licenses every year!

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e-Stage Video

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Conclusion

FEA, windtunnels, engineering, ...

2D to 3D Data

Engineering & design

AM/RP preparation

ProductionQuality control

Post processing &

shipping

Mimics 3-maticMagics

E-tools

Build processor

Mimics

3-matic

Formfit & Rapidfit+E-tools processor 3-matic Rapidfit+

+

+

29Streamics

Build processor

Manage installed printersout of 1 central location through an intuitive user interface

Add a printerwith only few mouse clicks

Configure your platform

Thank you!

Contact:karel.brans@materialise.be

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Print

Configure your platform

by defining platform properties

specific to a selected printer and consult real time machine information

Configure your partsby selecting properties for each individual part

Auto place your parts

Submit your print jobwith one mouse click

karel.brans@materialise.be