1. Seminário de Tecnologias2012
Innovations in Software for
Rapid Prototyping
Karel Brans
Business Development Manager – Software for Additive Manufacturing
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2. Content
• Introduction to Materialise
• Overview Software Solutions for Industrial RP
applications + Examples
• Engineering and Design on STL: 3-matic
• 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

3. 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...
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4. Introduction to Materialise:
Materialise Global Presence
Ukraine
Turkey
USA Japan
China
Hong Kong Taiwan
United
Kingdom
Czech Malaysia
Belgium Singapore
Republic
Germany
Austria
Italy
France
Spain
Portugal Australia
Production Unit Offices Agents

5. Introduction to Materialise:
3 Core Competences
Additive
Manufacturing
Medical
Image Based
Digital CAD
Engineering and
Manufacturing
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6. Introduction to Materialise:
3 Core Competences
1 Additive Manufacturing
• Layer by layer production of parts
(3D Printing)
• No need for tools,
only 3D design required
• 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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7. Introduction to Materialise:
3 Core Competences
2 Digital CAD
• Represent 3D volume by triangles
• Design automation

8. Introduction to Materialise:
3 Core Competences
3 Medical Image Based Engineering and Manufacturing
From CT/MR images
…to anatomical engineering
...to physical models

9. Introduction to Materialise:
3 Core Competences
Additive
Manufacturing
Medical
Image Based
Digital CAD
Engineering and
Manufacturing
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10. Introduction to Materialise:
3 core competences in 8 focused business units
SAM
AMS Software
for AM
.MGX RapidFit+
SOFTWARE
PRODUCTION
SERVICES
i.materialise Biomedical
Cranio-maxillofacial Orthopaedics
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11. Introduction to Materialise:
Software for Additive Manufacturing
SAM
AMS Software for AM
.MGX RapidFit+
SOFTWARE
PRODUCTION
SERVICES
i.materialise Biomedical
Cranio-maxillofacial Orthopaedics
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12. Overview Software Solutions for Industrial
RP applications
Post
2D to 3D Engineering AM/RP Quality
Production processing &
Data & design preparation control
shipping
FEA, windtunnels,
Magics
engineering, ... Build Mimics Formfit &
Mimics 3-matic
e-Stage processor 3-matic Rapidfit+
+
+
Streamics
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13. Engineering & design on STL
Lightweight technologies
Scaled models (wind tunnel)
wall thickness adjustements, design fixtures, add ribs for clay...
Texturing
aesthetic and functional textures
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14. Engineering & design on STL:
Topology Optimisation
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15. Engineering & design on STL:
Topology Optimisation
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16. 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

17. Engineering & design on STL:
3D Texturing
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18. AM preparation with Magics
Fix and Enhance and Prepare the Print better
Import files
prepare files edit data platform parts
Import nearly all Create waterthight Add logos, series Duplicate parts View slices
file formats and data numbers, etc Orient parts Detect collisions
native color Correct problems Apply textures Define no-build Save platforms
information Create short-cuts Perform boolean zones Generate reports
to suit your workflow operations
in a user-friendly Hollow parts
interface Perform cuts, ...
Magics AutoFab Suite is the ideal solution for professional
users of additive metal melting processes.

19. AM preparation with Magics
• Examples:
• Fixing
• Cutting
• Structures
• Sintermodule
• FormFit
• Trapped Volumes
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20. 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

21. AM preparation with Magics:
Magics Sintermodule - Powder Savings
Powder savings based on nest density increase from 6% to 7%
Nest density 6% Nest density 7%
Height 148 mm Height 126 mm
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22. AM preparation with Magics:
Magics Sintermodule - Powder Savings

23. AM preparation with Magics:
Magics FormFit: Solution for shipping parts
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24. e-Stage: Automatic Support
Generation for Stereolithography
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25. e-Stage: What is e-Stage?
what: single button solution for
intelligent & automated support generation
aim: optimize support for your application

26. 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
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
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27. 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
every year!
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28. e-Stage Video
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29. Conclusion
Post
2D to 3D Engineering AM/RP Quality
Production processing &
Data & design preparation control
shipping
FEA, windtunnels,
Magics
engineering, ... Build Mimics Formfit &
Mimics 3-matic
E-tools processor 3-matic Rapidfit+
+
+
Streamics
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30. Build processor
Thank you!
Manage installed printers
out of 1 central location
through an intuitive user interface
Add a printer
with only few mouse clicks
Contact:platform
Configure your
karel.brans@materialise.be
by defining platform properties
specific to a selected printer Print
and consult real time machine
information
Configure your parts
by selecting properties for
each individual part
Auto place your parts
Submit your print job
with one mouse click
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