Product Overview. Stereolithography. Mammoth Stereolithography. Laser Sintering. Fused Deposition Modelling. PolyJet (Objet) Z Corp.

Transcription

1 Product Overview Stereolithography Mammoth Stereolithography Laser Sintering Fused Deposition Modelling PolyJet (Objet) Z Corp Vacuum Casting Reaction Injection Moulding Hand Lay-up Additive Manufacturing Design and Engineering Services manufacturing.materialise.com prototyping.materialise.com Materialise OnSite

2 Overview of Materialise's Solutions Stereolithography Laser Sintering Fused Deposition Modelling PolyJet Fast visual and functional models with a high quality surface finish. Parts over 2m can also be built in a single piece. Functional and visual models for prototyping and low volume production applications (without the need for build supports). Highly accurate parts for prototyping and low volume production, which are directly produced in thermoplastic materials. Fast & accurate models with fine details in a wide range of materials. Courtesy of Pininfarina Courtesy of The Tussauds Studios, London Designed by Amanda Levete Courtesy of BERU f1systems Courtesy of Flama Zentrum See page 5 See pages 6&7 See page 8 See page 9 Materialise NextDay Service Materialise OnSite Service Additive Manufacturing Design and Engineering Services 24hour concept models > Instant online quotes & order system > Automatic 10% online discount > Available 24/7 The direct construction of production-grade components with complete design freedom in as little as 2 days. Our engineering team focuses on 3D Printing for manufacturing See page 4 See page 17 See page 11 See page 16 2

3 Z Corp Vacuum Casting R.I.M. Hand Lay-up Concept and architectural models directly printed in full colour. Highly functional and visual parts in a wide range of polyurethanes for low volume production. Functional and complex components for low volume production with low investment costs. Fast and cost-effective functional components for low volume production. Courtesy of Renault Truck SAS Courtesy of Kristof Briers Courtesy of Tandberg Courtesy of Krypton Courtesy of Bosch See page 10 See page 12 See page 13 See page 14 Techniques to enhance the performance of components Software for Additive Manufacturing Jan Hoogsteyns See page 15 See page 18 3

4 The Materialise NextDay Service Concept models in 24 hours Materialise started a 24 hour stereolithography service in 1997: the Materialise NextDay service. This was the first 24h service for online ordering of stereolithography prototypes - a revolution within the RP business - which gradually grew into the unrivalled success it is today. Parts ordered before 12 noon CET are shipped the same day. Quoting and ordering Materialise NextDay concept models Visit - where you can quote and order your parts online 24/7 in 4 easy steps (visit page 17 for more information on Materialise OnSite). Materialise NextDay prototypes > The Materialise NextDay stereolithography machines These machines build parts in 0.2mm layers and feature a patented curtain recoating system. These features enable parts to be built faster than on the standard commercialised stereolithography machines and allows us to deliver parts in record times. The Materialise NextDay machines are capable of producing parts with dimensions up to 650x650x480mm. Materialise NextDay prototypes are the ideal tool for the first design evaluation > The Materialise NextDay finish Materialise NextDay prototypes can be built in a wide range of high quality epoxy resins. In order to maximise speed without compromising quality, there is a dedicated finish for Materialise NextDay prototypes. Parts are taken from the build platform, excess resin and build supports are removed, the part is cured in a UV oven and any evidence of build supports on the model is sanded away. The high build speed of the patented Materialise NextDay machines, combined with this efficient finishing process results in the production of high quality concept models in the fastest possible lead-times. * subject to capacity limits. See full terms & conditions at Materialise NextDay prototypes WHY GO FOR MATERIALISE NEXTDAY? High-quality concept models Fast: 24 hours Cost-effective Instant quotations Easy to order Quote and order 24/7 4

5 Stereolithography Starting from a 3D image, a part is built slice by slice from bottom to top, in a vessel of liquid polymer that hardens when struck by a laser beam. Stereolithography is now one of the most widely used rapid prototyping techniques for plastic models and is the core process of our prototyping operations. Starting from your STL file, the required supports for overhangs and cavities are automatically generated on the model under construction. The support and model files are then cut into thin horizontal slices and programmed into the stereolithography machine. This machine then uses a computer controlled laser to draw the bottom cross section onto the surface of a liquid polymer that hardens where struck by the laser. The part is then lowered to a depth corresponding to the section s thickness and the next cross section is then drawn directly on top of the previous layer. This process is repeated until the part is completely constructed. The part is then removed from the machine and support structures are manually removed. Materialise uses a wide range of materials that combine high shape stability with attractive material properties. In order to precisely meet your requirements stereolithography parts can be finished by sandblasting, sanding or spray painting and can also be used as masters for casting techniques. Mammoth stereolithography dashboard in Pininfarina concept car Schematic overview of the stereolithography process Stereolithography is the ideal solution for > Show and tell parts with smooth surfaces and fine details > Visual prototypes for photo shoots, market testing and checking 3D drawings > Prototypes for limited functional testing > Masters for copying techniques (R.I.M. & vacuum casting) > Low volume production of complex geometries (see page 11) Giant prototypes, great knowledge Materialise has unrivalled knowledge in the production of large prototypes. Meeting the ever growing demand for larger and larger functional prototypes we decided to build our own patented Mammoth stereolithography machines. These machines have huge build platforms of 2100 x 700 x 800 mm enabling large components to be built in a single piece. Transparent body of concept car built using stereolithography (designed by Arturo Peralta) 1.86 m high Kouros statue built in a single piece Courtesy of Pininfarina The main application of these large stereolithography parts is as concept models, large master elements for R.I.M. and vacuum casting processes and the low volume production of complex geometries. In addition to these applications, the Mammoth models can also be further enhanced for use in more functional applications by employing various strengthening techniques (see page 15 for more information). WHY GO FOR MATERIALISE STEREOLITHOGRAPHY? Full scale BERU f1systems bicycle built using stereolithography and painted to the highest standard Fast: Parts in as little as 2 days High level of accuracy and high surface quality Representative parts for visual testing Functional parts Small and large parts from intricate switch component to car dashboard built in a single piece Wide range of finishing options Wide range of materials 5

6 Laser Sintering Laser sintered parts are built with successive layers of powder selectively bound by a laser beam. Laser sintering is also a technique by which parts are built layer by layer. The basic material consists of powder with particle sizes in the order of magnitude of 50 µm. Successive powder layers are spread on top of each other. After deposition, a computer controlled CO2 laser beam scans the surface and selectively binds together the powder particles of the corresponding cross section of the product. During laser exposure, the powder temperature rises above the glass transition point after which adjacent particles flow together. This process is called sintering. The materials We offer prototypes produced by laser sintering in a range of materials to suit your requirements. The standard material used for laser sintering is polyamide (PA) and polyamide filled with glass particles, aluminium particles or carbon fibres. As the powder is a solid material it has the attractive feature of being self-supporting for the generated product sections; this makes supports (typical for stereolithography) redundant. Polyamide and glass-filled polyamide enables the production of durable and strong prototypes required for fit, form and functional testing. The Alumide material has a metallic appearance, provides a high level of thermal resistance and can be post-machined. Parts produced using laser sintering can be made watertight by impregnation and a wide range of finishes can be achieved. Schematic overview of the laser sintering process Waste compactor assembly with functional laser sintered components Laser Sintering is the ideal solution for > Parts for mechanical and thermal tests Laser sintering enables the cost-effective production of strong and durable parts that can be used for extensive functional testing. Functional snap fits can be easily achieved and it is also possible to produce working hinges. Glass-filled PA and Alumide parts are perfectly suited for lighting elements, ventilation systems and products that require resistance to high thermal loads. Apart from their use as test products, the functional laser sintered parts are often the ideal and cost-effective solution for visual and dimensional checks. Architectural landscape constructed in multiple selective laser sintered materials The laser sintering material consists of powder which makes supports redundant 6

7 > Large and complex functional parts As the laser sintering process does not require build supports, this enables extremely complex geometries with internal details to be accurately produced. Our EOSINT P 730 machines can effectively build large and complex geometries in one piece up to 700 x 380 x 580 mm. Parts exceeding the P 730 s maximum dimensions can be built in multiple sections and bonded back together. The process of gluing sub-parts and assembling components can be executed in the most accurate and secure way using our unique RapidFit + system. The addition of our EOS FORMIGA P 100 machine enables an even quicker turnaround of complex laser sintered components, which also provides higher surface quality, finer feature details and the ability to produce wall sections as thin as 0.5 mm. Engine block component built on the EOSINT P 730 with a build volume of 700 x 380 x 580 mm > Low volume production by Additive Manufacturing Laser sintering is an excellent additive manufacturing solution which enables the direct construction of low volumes of production-grade components without having to invest in a mould. This provides short lead-times, instant design modifications, complete design freedom and the ability to completely personalise every part. See the Additive Manufacturing section on page 11 for more details. Quin.MGX pendant lamp WHY GO FOR MATERIALISE LASER SINTERING? Fast Economical Durable and functional parts Large and complex parts Direct production of low volume projects Design freedom (no support structures necessary) Wide range of finishing degrees Can be sealed watertight Laser sintered headrest for Renault Ondelios concept car 7

8 Fused Deposition Modelling The Fused Deposition Modelling (FDM) process constructs threedimensional objects directly from 3D CAD data. A temperaturecontrolled head extrudes thermoplastic material layer by layer. The FDM process starts with importing an STL file of a model into a pre-processing software. This model is oriented and mathematically sliced into horizontal layers varying from +/ to 0.25 mm thickness. A support structure is created where needed, based on the part's position and geometry. After reviewing the path data and generating the toolpaths, the data is downloaded to the FDM machine. The system operates in X, Y and Z axes, drawing the model one layer at a time. This process is similar to how a hot glue gun extrudes melted beads of glue. The temperature-controlled extrusion head is fed with thermoplastic modelling material that is heated to a semi-liquid state. The head extrudes and directs the material with precision in ultra-thin layers onto a fixtureless base. The result of the solidified material laminating to the preceding layer is a plastic 3D model built up one strand at a time. Once the part is completed the support columns are removed and the surface is finished. Flama Zentrum coffee maker in polycarbonate Supports FDM offers two types of support structure; break away support structure (typical of stereolithography) and water-soluble support structure (WaterWorks). WaterWorks uses a soluble material that is dissolved in a water/solvent solution, enabling to simply wash away the model supports. This means that supports can be located in concealed regions of parts, as the manual removal of supports typical of other technologies is eliminated. Your model will be left smooth and clean leaving the fine details intact. Thanks to the WaterWorks supports system, an integrated multi-piece assembly can be constructed in a single build. The materials The material properties are one of FDM's greatest strengths: FDM uses thermoplasts including different grades of ABS, PC, blends of ABS and PC, PPSU and ULTEM These materials provide matches to the intended production materials. For example, an ABS prototype has up to 80% of the strength of injected moulded ABS component, meaning that it is extremely suited for functional applications. Other great advantages of the FDM materials is the durability, the stability of the mechanical properties over time and the build accuracy of the parts. See datasheets for more detailed information on available materials. Additive Manufacturing FDM is an excellent additive manufacturing solution which enables the direct construction of low volumes of production-grade components without having to invest in a mould. This provides short lead-times, instant design modifications, complete design freedom and the ability to completely personalise every part. See the Additive Manufacturing section on page 11 for more details. FDM is the ideal solution for > Prototypes for functional testing; you can install and run the parts in your production intent material for the best possible proof that your design really works > Prototypes for form and fit testing > Prototypes directly constructed in production materials > Quality parts with a high stability > Durable single piece parts up to 600 x 500 x 600 mm > Low volume production (Additive Manufacturing see page 11) A series of ABS fixtures directly printed using FDM technology WHY GO FOR MATERIALISE FDM? High accuracy Functional parts Water-soluble support structure Production materials Durable parts with great stability Short throughput times thanks to large capacity Customised production-ready Zagato headlight printed in ABS and metalised 8

9 PolyJet (Objet) PolyJet technology enables horizontal layers of just 16µ (0.0006"), fine details, and ultra-thin walls down to 0.6 mm (0.024") depending on geometry. Objet s patented PolyJet inkjet technology works by jetting state of the art photopolymer materials in ultra-thin layers (16μ) onto a build tray layer by layer until the part is constructed. Each photopolymer layer is cured by UV light immediately after it is jetted, producing fully cured models that can be handled and used immediately, without post-curing. The gel-like support material, which is specially designed to support complicated geometries, is easily removed by hand and water jetting and in turn minimizes post-finishing. Visual model with vacuum metalised finish for Tussauds Studios Connex multiple materials The materials The wide variety of materials available enables rigid, rubber-like or even multi-material models to be directly produced. The general purpose Objet VeroWhitePlus is white in color and offers enhanced mechanical properties and the ability to withstand bending. This material enables the production of highly accurate models which are ideal for fit, form, function, and visual testing. Objet s TangoPlusBlack is a flexible rubber-like resin and offers exceptional elongation at break, making it suitable for prototypes of components like seals, non-slip surfaces etc. It is ideal for models that are likely to be exposed to extensive use or rough handling. There are also seven composite materials available (Shore A40 Shore A50 Shore A60 Shore A70 Shore A85 Shore A95) with present combinations of mechanical properties, ranging from Shore A40 with a tensile strength of and an elongation at break of , to the Shore A95 with a tensile strength of and an elongation at break of The PolyJet technology provides the opportunity to directly build parts and assemblies consisting of multiple materials, which saves time and money by avoiding cutting, gluing and overmoulding techniques. This technology also enables multiple materials to be mixed together in various concentrations, which produces parts that match the specific Shore A values of your intended production material. PolyJet is the ideal solution for > Visual models with fine details & smooth surfaces > Rubber-like prototypes > Multi-material parts > Parts to match specific Shore A values > Masters for copying techniques (vacuum casting) Accurate models built in VeroWhite for fit testing WHY GO FOR MATERIALISE POLYJET? Fast High accuracy Fine details Variety of materials available Smooth and durable surfaces Multi-material parts directly produced Outstanding surface finishing possibilities 9

10 Z Corp 3D printing uses standard inkjet printing technology to create parts layer-by-layer by depositing a liquid binder onto thin layers of powder. Instead of feeding paper under print heads like a 2D printer, a 3D printer moves the print heads over a bed of powder upon which it prints the cross-sectional data. Coloured models are created by using colour heads for the printing. The powder is distributed accurately and evenly across the build platform by using a feed piston and platform, which rises incrementally for each layer. A roller mechanism spreads powder fed from the feed piston onto the build platform. Once the layer of powder is spread, the inkjet print heads print the cross-sectional area for the first, or bottom slice of the part onto the smooth layer of powder, binding the powder together. A piston then lowers the build platform by 0.1 mm, and a new layer of powder is spread on top. The print heads apply the data for the next cross section onto the new layer, which binds itself to the previous layer. This process is repeated for all of the layers until the physical model is created. Z Corp is the ideal solution for > Fast & cost-effective concept models > Full coloured models (Architecture, G.I.S.models) Full colour architectural model designed by Kristof Briers Concept model of toothbrush Highly detailed architectural model WHY GO FOR MATERIALISE Z Corp? Fast Printed directly in full colour Cost-effective 10

11 Additive Manufacturing Additive manufacturing is the collective term for layer by layer additive fabrication processes, which enable the direct rapid construction of production-grade parts without having to invest in a mould. This has obvious cost and lead-time advantages and also provides increased design freedom and the ability to instantly modify the design by simply printing the modified file. Unrivalled capacity Materialise, with the World's largest 3D Printing capacity based at one location, is placed in pole position to offer world class low-volume solutions by utilising additive manufacturing technologies..mgx a brand dedicated to Additive Manufacturing Materialise was so convinced by the advantages of additive manufacturing, in 2004 the.mgx brand was created..mgx is dedicated to the successful creation of unique and personalised design products manufactured with Materialise additive manufacturing technologies. The primary Additive Manufacturing processes > Laser Sintering Laser sintering is often an interesting and cost-effective alternative to mould based low volume production techniques such as injection moulding. With the EOSINT P 730 machines which have large build areas, a small series of production-grade components can be manufactured in one single laser sintering process. The nesting of components into a single sintering process, combined with the fact that no mould is required, drastically decreases the price of a small production series. Materials available include PA11, PA12, PA-GF, Alumide, PA 2241 FR and TPU 92A-1. > Fused Deposition Modelling Fused deposition modelling (FDM) is a technology which produces superior production-grade functional components. The great advantage of this technique originates from the thermoplastic materials used, which provides an accurate representation of mechanical properties, stability of the mechanical properties over time and a high level of dimensional quality. FDM technology is often an attractive alternative to mould based production techniques as it enables design changes on the fly, by simply updating the file while maintaining accurate representation of mechanical properties. With the largest in-house FDM capacity in Europe we have the resources to comfortably handle large orders. The wide range of thermoplastic materials available includes ABS (various colours available), ABSi, AMBS-M30, ABS-M30i, ABS-ESD7, PC, PC-ISO, PC-ABS, PPSU and ULTEM Please visit page 8 for more information on FDM. > Stereolithography Stereolithography is widely known for its success in the rapid prototyping field, however it also provides excellent additive manufacturing solutions in many scenarios. Stereolithography excels as an additive manufacturing technique in terms of a fast turnaround, excellent surface quality and in the case of Materialise s patented Mammoth machines, build size also (2100 mm x 700 mm x 800 mm). With an extensive capacity of stereolithography machines, a wide range of ever improving materials and patented Mammoth stereolithography machines, Materialise is able to offer a world class additive manufacturing service. Please visit page 5 for more information on stereolithography. Additive Manufacturing is the ideal solution for production-grade components which > are required in low volumes > are required in 2 working days > have complex geometries > need to be weight saving > require individual personalisation A series of propellers directly printed using laser sintering A series of ABS fixtures directly printed using FDM technology SL allows complex designs such as the Lotus.MGX lamp to be produced and commercialised WHY GO FOR ADDITIVE MANUFACTURING AT MATERIALISE? Fast (production-grade parts in as little as 2 days) Instant design modifications Low investment costs (no mould required) Complex geometries possible Wide range of functional materials 11

12 Vacuum Casting Vacuum Casting is a fast low-volume copying technique using a flexible silicone mould. A master component is manufactured using a rapid prototyping machine (usually a carefully finished stereolithography or machined model) and silicone is cast around the master. After curing, the silicone block is cut open and the master is removed to leave a flexible mould. A wide range of two component polyurethanes with different mechanical and aesthetic properties can then be fed into the silicone mould under vacuum (to avoid bubbles). The mould is then placed into an oven until the polyurethane component has fully cured. The component is subsequently ejected from the mould and thanks to the flexibility of the silicone it is easier to demould undercuts without the need for slides or additional parting planes. Additional finishing can then be performed on the casting if required. Mammoth Stereolithography technology equals large castings The 2100 x 700 x 800 mm build platform of our patented Mammoth stereolithography technology enables master components as large as 2m to be built in a single piece. The machine also features a patented curtain recoating technology which reduces the dead time between layers, enabling large components to be manufactured in only a few days. Our Mammoth technology avoids the need to cut large masters into many sections and re-bond, which in turn provides a superior surface finish, a quick turnaround and optimal dimensional accuracy. Vacuum cast sander Belt with casted inserts United vacuum casting power - Materialise & GrupoVangest form VCRM Materialise have joined forces with GrupoVangest, the Portuguese specialist in rapid manufacturing and tooling solutions with renowned expertise in high-speed milling of complex and accurate components. The collaboration provides an integrated rapid manufacturing service known as VCRM. This partnership will provide Materialise customers with access to an extensive and flexible capacity of 70,000 vacuum castings and machined parts per year, along with the combined expertise of Materialise and GrupoVangest. Vacuum casting is the ideal solution for > Pre-launch testing > Low-volume production > Visual models WHY GO FOR MATERIALISE VC? Tandberg conferencing screens for market research and functional testing Cost-effective for low volumes Functional plastic parts Wide range of colours/textures Broad range of materials (rigid & rubber parts) Large castings up to 1900 x 900 x 750 mm Multi-material parts via overmoulding Large capacity 12

13 Reaction Injection Moulding Reaction Injection Moulding (R.I.M.) is a technique to produce plastic parts by the low-pressure injection of thermoset resins in moulds. R.I.M. moulds are produced in different materials, including resin moulds which are the most frequently used. Materialise focuses on small series moulds, built around a master part produced by rapid prototyping methods such as stereolithography or HSM. Different types of moulds are used depending on the quantity, size of the part and speed required. We offer the following approaches based on quantity requirements. 1. Directly machined tools; no master needed > Ureol tools ( mouldings) 2. Master based tools > Silicone tools (10-50 shots) > Resin tools with fibre reinforcement ( parts) > Resin tools with aluminium backing ( parts)* The materials Two component materials are used, which polymerise through crosslinking after mixing. The most commonly used materials are polyurethanes (PUs,) which includes temperature resistant PU, flame retardant PU (UL94V0 norm), shock resistant PU etc These materials allow the prototyping and low volume production of mechanically functional products, which is a typical application in the automotive sector. The production cycle time is relatively short allowing a throughput of about 30 parts per week (dependent on size and complexity). Lid seating part manufactured using R.I.M. for Sulo Giant parts and extensive automotive knowledge The 2100 x 700 x 800 mm build platform of our patented Mammoth stereolithography technology enables master components as large as 2m, such as bumpers and dashboards to be built in a single piece. Our Mammoth technology negates the need to cut large masters into many sections and re-bond, which in turn provides a superior surface finish, a quick turnaround and cost-effectiveness. Automotive R.I.M. castings are available in a wide range of materials which closely match the properties of the final product. R.I.M. products also have a good surface finish, which is an important factor when the parts require (texture) painting or coating, e.g. interior trim and lining elements. R.I.M. is the ideal solution for the low volume production of > Large and complex automotive components > Durable medical housings with a high quality finish Renault truck production-ready grill produced using R.I.M. * dependent on part complexity and R.I.M. material WHY GO FOR MATERIALISE R.I.M.? Short lead times Low tooling investment cost Wide range of materials with properties close to final product Ideal for large and complex parts with thick wall sections Surface finish permits high quality painting Ideal for small series ( /year), e.g for medical equipment THE PARTS are 100% functional can be flame retardant have a high impact strength can be painted to enhance appearance 13

14 Hand Lay-up The principle of hand lay-up is very simple: in contrast with R.I.M., it requires only one half of a tool and in most cases the mould half of the A-face. On this tool half, a shell is created (by hand laying) with resins and glass or carbon fibre sheets. Components can be used for aesthetic purposes as well as functional testing. In the latter case, the functional elements (like screw bosses, clip boxes, ribs, etc) are made using our laser sintering machines and inserted into the shell of the component. Two types of resins can be used: > Epoxy Epoxy systems have the advantage of longer setting times, therefore the shell thickness can go up to 15 mm (applied in a single operation) and temperature resistance can be increased to 190 C after post-curing. Epoxy systems require about 24 hours curing time before the shell can be de-moulded from the tool half. The use of epoxy resin results in components with a high level of mechanical performance and durability. > Polyester The process of using polyesters is identical to that of epoxies, but the polymerisation rate is 6 to 8 times higher with polyesters. The shell thickness is limited to around 3 mm, but can be applied in successive layers on top of each other (even if the previous layer is fully cured). The use of polyester resin also enables the cost-effective production of parts. The supports The supports for the fabrication of the shells can be created in different ways: > From a stereolithography master > From an existing component supplied by the customer > By directly machining urethane plates (Ureol, Renwood), dependant on the density required to produce the desired quantity of parts Frontcover Krypton measuring unit in R.I.M. WHY GO FOR MATERIALISE HAND LAY-UP? Low investment costs (only half a mould is required) Functional parts Cost-effective for large parts in limited numbers 14

15 Techniques to enhance the performance of components In line with Materialise s strive to offer the optimal tailored solution, a wide range of unique services are available to ensure that your exact project requirements are met. Full scale metalised automotive B-pillar Metal plating Metal plating is a process that can be performed on rapid prototypes produced using stereolithography, laser sintering or FDM techniques. Depending on the surface requirements of the final component, the part will be finished smooth and then undergo the metal plating process. The process consists of the application of a layer of copper and optionally nickel to the rapid prototype. The thickness of these layers can be controlled and are in the order of magnitude of 0.05 mm each. A particularly unique metal plating service which Materialise offers, is to metal plate parts produced on the patented Mammoth stereolithography machines. This enables parts over 2m to be metal plated such as automotive B-pillars. > Advantages of metal plating: > Increase mechanical strength > Increase creep characteristics > Increase aging stability > Increase heat resistance > Increase chemical resistance > Fast production of metal parts > Applications of metal plating: > Replacements for solid metal parts > Flame retardant components > EMC shielding > Parts requiring resistance to humid and corrosive environments > Parts requiring a metal appearance Glass/carbon fibre reinforcement This involves carefully adhering thin sheets of glass/carbon fibre sheets, usually to the non-visual face of components. This can drastically increase the durability and mechanical strength of rapid prototypes and R.I.M. components and is typically used for large parts such as car bumpers, dashboards and trunks. This reinforcement process provides the perfect tailored solution for projects that require the superior surface finish provided by some of the less durable materials but also requires a high degree of strength and durability. Philips Achieva 3.OT TX MRI-scanner manufactured using stereolithography and reinforced with glass fibre for increased rigidity and durability Honeycomb reinforcement Using our internally developed 3-matic software, we can semiautomatically apply a honeycomb structure directly to.stl files, which saves costs by minimising the volume of the component while maximising the strength. BMW Mini door panel with honeycomb reinforcement applied using 3-matic 15

16 Design & Engineering Services Our engineering team focuses on 3D Printing for manufacturing With its huge degree of design freedom, 3D Printing has introduced a new way of thinking about design. Our team of creative engineers knows how to build a design specifically for 3D Printing. If you truly want to get the most out of these technologies, get us involved in your project in the design phase. Materialise has an international team of 15 highly specialized designers and CAD engineers who support customers in different industries with dedicated design for Additive Manufacturing. The engineering team is supported by more than 80 Additive Manufacturing machines, specialists for every technology and a battery of software developers Materialise helped Jaguar engineers realize a durable CX-75 concept car by adding the required internal strengthening ribs and structures. In partnership with Data optimization for Rapid Prototyping Our engineering team will help you with your most challenging prototype projects with the following services: > File repair of scanned data or CAD assemblies > Creation of 3D file (B surface design) starting from A-face data > Complex cuts > Generation of reinforcement structures > Fast creation of scale models for wind tunnel testing and other applications Design for Additive Manufacturing Having the world s largest in-house Additive Manufacturing production capacity under one roof, our design engineers know the strengths and limits of Additive Manufacturing technologies better than anyone. We work with you to: > Maximize functional integration > Align design with material and technological strengths > Maximize consistency > Minimize costs Surface texturing Thanks to Materialise s 3-matic software, textures can be applied directly on a STL file of complex 3D shapes which can then be printed. This is the only way to realize prototypes that include real texture. Texturing also provides extra value to your Additive Manufacturing projects by adding aesthetics or functionality. The Materialise Clever Design Wall showing the possibilities of 3D Printing. Lightweight structures created with Materialise s 3-matic software Lightweight structures One of the key advantages of Additive Manufacturing is the flexibility to create shapes which are impossible or too costly to produce with traditional technologies. Our engineers can optimize your designs and translate them into lightweight components. Materialise adds texture to Samsonite s S-Cure prototype 3D Printed with Mammoth Stereolithography. 16

17 The Materialise OnSite Service Your entry to an unlimited prototyping capacity! Materialise OnSite is a comprehesive online quote and order platform which brings Materialise's full prototyping capability to your own office and helps you to save time and money. Materialise OnSite is the ideal solution for > Instant quoting and ordering of prototypes 24/7 > Minimising prototyping costs (instant 10% online discount) > Uploading large files for quotation > Tracking your Materialise orders > Viewing our machines in operation Simple online ordering: The whole Materialise OnSite process is internet-based: when at you can complete your online quote and order in an easy 4 step process: 1. Register or login 2. Click Quote Now and view the price 3. Specify the delivery address 4. Confirm order Wide range of technologies available > NextDay Stereolithography > Stereolithography > Fused Deposition Modelling > Laser Sintering > PolyJet A wide range of finishes are available, from the basic removal of supports to textured models matching a specified RAL colour. Fully finished high gloss stereolithography models like this, can be quoted and ordered at Materialise OnSite Materialise OnSite demo produced using laser sintering WHY GO FOR MATERIALISE ONSITE? 10% instant online discount Available 24/7 100% secure (.STL file is only uploaded upon order) Fast and user friendly Estimated lead-times Project tracking facility Upload of large files 17

18 Software for Additive Manufacturing A vital factor contributing to the efficiency and success of Materialise prototyping and low volume production operations is the use of Materialise s innovative software solutions. Materialise leads the development and provision of integrated software products and services for the RP&M (Rapid Prototyping & Manufacturing) professional. These leading software solutions automate the entire RP&M workflow from the 3D CAD file all the way to the final product, including data management and resource planning. Optimal efficiency In order to provide cost-effective solutions with the shortest lead-times in the industry, it is essential that the most efficient software is employed to ensure optimal performance. > Advanced work preparation In order to provide unique rapid prototyping and manufacturing solutions to our wide range of customers, we need to perform many file operations to adapt or prepare files for building on a rapid prototyping machine. Such operations include automatic file fixing, nesting, cutting of STL files, automatic support generation, slicing of STL files and import of STL files. Magics, the professional software solution for rapid prototyping and manufacturing professionals proves to be the ideal solution for these requirements. > Automated design operations With the World s largest rapid prototyping capacity in one location, we build many parts on a daily basis. In order to offer this extensive capacity in conjunction with cost-efficiency and the shortest lead-times in the industry, it is imperative that we automate as many operations as possible. This is why we use Streamics, developed by Materialise, to automate and control several steps of the rapid prototyping and manufacturing file preparation stage, for example fixing, parameter, and preview generation tasks, but also labeling, nesting and support generation. > Optimal communication, planning, data management and tractability In our strive for optimal efficiency, Streamics is a reliable tool for project and process management. This enables our projects (from initial sales data all the way through to shipment tracking) to be managed and shared on one central system. This facilitates machine and project planning and ensures full part and process tractability. Advanced design modifications > Repair and design changes without reverse engineering We often have requests from customers to scan an object for which no CAD data exists. The scanning process is often unable to capture all the information to automatically recreate the complete geometry of an object, which subsequently leads to the geometry requiring healing and reconstruction. However, instead of reverse engineering the scan data and taking it back to CAD for repair and design changes, we use 3-matic software to execute repairs and design changes directly on the STL file. This enables us to save significant amounts of time and avoids the errors associated with reverse engineering back to CAD. > Free STL viewer: MiniMagics software > Free STL viewer: MiniMagics software Download our free MiniMagics software: a.stl file viewer that allows you to import, save and compress.stl,.magics and.mgx files, as well as view parts and detect bad edges and flipped triangles. To download visit software.materialise.com/minimagics We can automatically apply textures directly to part surfaces using Materialise s e-texture tool Scan data of Holden Engineering casting pattern. The broken pattern (for which there was no CAD data) was scanned and redesigned (on STL level), using 3-matic software without going back to CAD 18

19 Materialise, and any and all Materialise brand, product, service and feature names, logos and slogans mentioned in this document are registered trademarks and/or trade names of Materialise and are protected by trademark laws in the Benelux or other countries. All other brand, product, service and feature names or trademarks are the property of their respective owners. No user has any right, title, or interest in those marks or names not previously expressly granted in writing to such user by Materialise.

20 Headquarters - Belgium Technologielaan Leuven Belgium T F E projects@materialise.be VAT: BE France ZAE Rue Germinal Saint Marcel les Valence T F E projet@materialise.fr Germany Friedrichschafener Str Gilching T F E projekte@materialise.de Czech Republic Predlicka 460/ Usti nad Labem T F E projekty@materialise.cz Austria Gutheil-Schoder-Gasse Wien T F E prototype@materialise.at United Kingdom AMP Technology Centre Advanced Manufacturing Park Brunel Way Catcliffe S60 5WG Sheffield T F E projects@materialise.co.uk Spain T E proyectos@materialise.com Scandinavia T E projects@materialise.se Italy E progetti@materialise.com For information on particular technologies or materials, visit: prototyping.materialise.com or manufacturing.materialise.com