Printed Parts

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Mannequin

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Female mannequin
Cock-up splint
Cock-up splint Image

Technical specifications:

Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated.

Technology highlights:

3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company’s production volume) in a controlled and efficient way.

The translation of a CAD model – which is built from a corrected 3D scan – into a fully digital production process enables Aqtor! to work faster and more efficiently.

Thanks to 3D-printing, products are much lighter and more flexible than traditional products and can be precisely modelled to the patient’s body for a better fit.

Information and use cases:

With 3D-printed projects (Rescue-corset, Cock-up splint and Prosthetic sleeve) Aqtor! Is building the groundwork for the future of modern technical orthopaedics: ‘the digitalization of craftsmanship’.

New 3D techniques are used to achieve faster turnaround times, achieve higher accuracy, produce less waste and optimize the product (e. g. through lightweight structures, minimal material use, integration of additional features such as closures, straps, etc.). Moreover, these 3D-printed designs ensure a better fit and offer a wide spread of pressure points with the advantage of extra comfort when wearing. In addition, these 3D-printed products are customizable in colors and patterns, but also with name and text.

In short, the development of 3D-scanning, modelling, 3D-printing and assembly will change the traditional craft of orthopaedics.

 

Rescue-corset
Rescue-corset Image

Technical specifications:

Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated.

Technology highlights:

3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company’s production volume) in a controlled and efficient way.

The translation of a CAD model – which is built from a corrected 3D scan – into a fully digital production process enables Aqtor! to work faster and more efficiently.

Thanks to 3D-printing, products are much lighter and more flexible than traditional products and can be precisely modelled to the patient’s body for a better fit.

Information and use cases: 

With 3D-printed projects (Rescue-corset, Cock-up splint and Prosthetic sleeve) Aqtor! Is building the groundwork for the future of modern technical orthopaedics: ‘the digitalization of craftsmanship’.

New 3D techniques are used to achieve faster turnaround times, achieve higher accuracy, produce less waste and optimize the product (e. g. through lightweight structures, minimal material use, integration of additional features such as closures, straps, etc.). Moreover, these 3D-printed designs ensure a better fit and offer a wide spread of pressure points with the advantage of extra comfort when wearing. In addition, these 3D-printed products are customizable in colors and patterns, but also with name and text.

In short, the development of 3D-scanning, modelling, 3D-printing and assembly will change the traditional craft of orthopaedics.

Prosthetic sleeve
Prosthetic sleeve Image

Technical specifications:

Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated.

Technology highlights:

3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company’s production volume) in a controlled and efficient way.

The translation of a CAD model – which is built from a corrected 3D scan – into a fully digital production process enables Aqtor! to work faster and more efficiently.

Thanks to 3D-printing, products are much lighter and more flexible than traditional products and can be precisely modelled to the patient’s body for a better fit.

Information and use cases:

With 3D-printed projects (Rescue-corset, Cock-up splint and Prosthetic sleeve) Aqtor! Is building the groundwork for the future of modern technical orthopaedics: ‘the digitalization of craftsmanship’.

New 3D techniques are used to achieve faster turnaround times, achieve higher accuracy, produce less waste and optimize the product (e. g. through lightweight structures, minimal material use, integration of additional features such as closures, straps, etc.). Moreover, these 3D-printed designs ensure a better fit and offer a wide spread of pressure points with the advantage of extra comfort when wearing. In addition, these 3D-printed products are customizable in colors and patterns, but also with name and text.

In short, the development of 3D-scanning, modelling, 3D-printing and assembly will change the traditional craft of orthopaedics.

Cranioplasty implant
Cranioplasty implant Image

Technical specifications:

Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM).

 

Technology highlights:

The PEEK cranioplasty implant serves to protect the patient’s brain when a large bone defect is present. The implant is designed specifically for the patient, based on a CT-scan of his/her skull.

The perfect fit between implant and skull defect reduces the time (and thus cost) in the OR significantly. The patient specific design by engineers allows a perfect esthetic outcome by mirroring the skull curvature of the healthy, unaffected side to the affected side.

 

Information and use cases:

The PEEK cranioplasty is readily available through all of Europe since the very beginning of CADskills.

 

Total temporomandibular joint prosthesis
Total temporomandibular joint prosthesis Image

Technical specifications:
Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM).

Technology highlights:
The total TMJ (temporomandibular- or jaw joint) prosthesis is partly 3D-printed in titanium. This technique was chosen because it allows the integration of a scaffold into the implant that promotes the ingrowth of tissues.
At the inner, bone touching side, the scaffold enables osseointegration (bone ingrowth into the implant), leading to a strong and stable connection, as the bone and implant unite. Higher up, near the condyle, the scaffold allows the attachment and ingrowth of the pterygoid muscle, which would otherwise become useless. This muscle is extremely important to maintain the natural feeling and lateral movement of the lower jaw for the patient. CADskills is the only TMJ prosthesis manufacturer worldwide that incorporates this feature and has patented it.

Information and use cases:
The TMJ prosthesis has recently been launched for clinical use. However, CADskills is already working on a second generation. The goal is to go one step further in patient specific solutions to obtain the holy grail. By designing a prosthesis that is perfectly collaborating with the natural joint on the contralateral side, a longer prosthesis lifetime, full natural mouth opening and full rehabilitation comes in sight.
These technologies are also applied to other fields like to dental rehabilitation (AMSJI) and is being transferred to orthopedics.

Spinal column vertebrae
Spinal column vertebrae Image

Technical specifications:
Printed in DSM Somos® Watershed XC 11122 using Stereolithography (SLA) technology.

Technology highlights:
As one of the industry’s most popular materials, Somos® WaterShed XC 11122 is the obvious solution for numerous applications. Whether you’re a designer looking for highly detailed parts with superior clarity and water resistance, or an engineer focusing on durability for functional testing, Somos® WaterShed XC 11122 mimics the look and feel of clear thermoplastics, such as ABS and PBT.

Information and use cases:
Somos® Watershed XC 11122 was used to create a 3D printed inlet manifold that allowed one of the world’s leading automotive engine manufacturers, Rausch Yates Engines, to test the design durability. In addition, the clarity allowed them to see fuel build-up during testing which enables design changes to be made prior final part production. This has provided Rausch Yates with a competitive edge and shortened their development cycle.

Anatomical heart
Anatomical heart Image

Technical specifications:

Printed using SLS technology in PA2200. SLS-printing is very suitable for producing both small and larger series. As no support structures are required, a large complexity of the components can be obtained.

Information and use cases:

Tenco DDM aims to co-create high-end solutions with customers, by means of 3D-printing or CNC-machining. They offer a perfect fit to ensure a personal and tailormade service and support in additive manufacturing and innovative finishing techniques. The model of the heart can be used in hospitals to evaluate cases before or during surgery, yet many other applications are feasible or conceivable.

Hip implant
Hip implant Image

Technical specifications:

Printed at ESMA with SLM technology in Ti64 on a Renishaw AM250. Heat-treated through Hot Isostatic Pressing (HIP) at Bodycote HIP.

 

Technology highlights:

Where initially cobalt-chromium alloys were selected as bio-compatible materials for medical implants, today these are commonly replaced by the much lighter titanium based alloy Ti64. By designing a scaffold structure on the inside, this hip implant becomes truly lightweight, yet remains as strong as a densely printed or machined part. But the main benefit is of course the possibility to entirely adapt the shape of the implant to the patient. To reduce friction, a ceramic coating has been applied on the ball joint.

 

Information and use cases:

By combining AM technology with CNC turning and milling, ESMA is able to manufacture complete products. ESMA used the Renishaw metal powder bed fusion technology, and is capable of printing in cobalt-chrome and titanium for dental, medical and industrial markets.

Renishaw’s Metal Additive Manufacturing allows parts to be built with few limitations in geometry. Living hinges, interlocking parts, thin wall and hollow objects are possible offering technological benefits, such as patient specific production and the ability to co-print both solid and porous structures promoting ingrowth into the human body. Renishaw is specialised in developing precision equipment to optimise production processes and maximise the output.

Metal and ceramic Additive Manufactured parts often require post-printing heat treatments and specialist thermal processing such as Hot Isostatic Pressing (HIP) to bring the mechanical properties of printed parts to their full potential. In HIP processing parts are subjected to sustained high temperatures and a very high inert gas pressure, resulting in the full removal of porosities. This typically leads to a significant increase of the component’s elasticity and life time.

Temporary Crown & Bridge (teeth)
Temporary Crown & Bridge (teeth) Image

Technical specifications:

Printed with light-curing composite for temporary crown and bridge using SLA technology.

Technology highlights:

In order to serve the demand in the dental market, GC started the development of dental 3D-printable materials. Based on its 97 years of background in dental materials, and specialized in light curing materials, the choice of using SLA (Stereo Lithography Apparatus) as 3D-printing technique was obvious. Nevertheless, the precision of the end product may vary, depending on the geometrical design, device and orientation of the printed part, as well as the material properties itself. Every 3D-printed realization in dental applications, is unique as very person has a different anatomical tooth shape.

Information and use cases:

The first 3D-printing products of GC were shown at the international dental fair IDS 2017, being a model and a temporary bridge with CE certified material. The first clinical application, a 7-unit bridge, was placed in a patient’s mouth in August 2017. It was experienced as a very easy to handle material for both dentist and dental technician, and it was perceived by the patient as very comfortable and aesthetic.

The product will be launched on the European dental market in 2018.

Lower leg
Lower leg Image

Technical specifications:

Laser metal deposition (‘laser cladding’) technology with 316L stainless steel powder.

Technology highlights:

The LCV-Form benefits are design freedom, fast delivery, and high speed 3D-printing: LCV prints a 500 mm high manifold in less than 3 hours. This opens new possibilities for Near Net Shape (NNS) 3D-printing. Applications include gears, cutting tools, punching dies, etc.

Information and use cases:

With 3D-printing by means of laser metal deposition, tracks of molten metal are applied to a base plate or substrate. These metal tracks are deposited in layers by melting a powder (which can be supplied co-axially or laterally) by means of a laser. Stacking these metal tracks on top of each other enables us to create three-dimensional objects. Since multi-axis laser nozzles and substrate clamps are used, there is no need for a powder bed. This opens up new degrees of design flexibility.
This additive shaping technology enables specific structures and even gradient materials to be built up on existing substrates.

Ceramic inteverbral
Ceramic inteverbral Image

Technical specifications:

Silicon carbide intervertebral printed using SLS technology.
 

Technology highlights:

Via Selective Laser Sintering, small silicon and silicon carbide powder particles can be fused together to form a Silicon-Silicon Carbide preform. After post-processing, a near-fully dense ceramic part is obtained. The use of AM for the production of ceramics allows for more design freedom and could open up new possibilities for these materials. Si-SiC for example is light, stiff and has excellent thermal properties, which makes it a suitable candidate for various applications in the aerospace or micro-electronics industry.
 

Information and use cases:

KU Leuven has 30 years of AM experience. Material development in all technical classes is a main focus. Ceramics have historically been challenging to form into complex shapes. By using selective laser sintering, high temperature technical ceramic materials can be produced with a high degree of design freedom. Laser sintered Si-SiC is currently not yet available on the market.

Insole with pressure monitoring
Insole with pressure monitoring Image

Technical specifications:

Printed using Filament Deposition Modeling (FDM): a low-cost technology offering solutions for high-end challenges.

Technology highlights:

Embedded pressure sensors continuously monitor step behavior; it is the integration of “smartness” in the design that turns a relatively simple 3D-printing technique into a true solutions-builder.

Information and use cases:

Many researchers at the VUB are active in the field of prosthesis development. Using electric motors and springs, active prostheses control the movement of knee and ankle, based on a step pattern. The actuation of the prosthesis is based on the feedback of a step monitoring device. The integration of pressure monitoring inside a 3D-printed insole serves as feedback for the step controller, allowing actuating ankle and knee in time. Being less painful than other step monitoring devices and suitable for use in out-of-lab conditions, it is a suitable solution for active prosthesis control.

Fully 3D-printed glasses
Fully 3D-printed glasses Image

Technical specifications:

The eyewear frame was printed in titanium (TiAl6V4) using DMLS – powder bed technology. The lenses were printed in E-Shell 600 biocompatible material.

Technology highlights, information and use cases:

The eyewear frame, produced by Raytech, is completely 3D-printed in titanium which makes it light, durable, rust-proof and anti-allergic. By using metal 3D-printing, unique products can be manufactured tailor-made and fully personalized.

Tenco DDM printed tailor-made lenses. Transparent glasses have been printed using DLP technology in bio-compatible material and both mechanically and chemically polished. Using 3D-printing, fully transparent parts can be generated to evaluate liquid flows, to evaluate optical models and to make end-use parts as the transparent material is UV stable. Patrick Hoet, creator of world’s first metal 3D-printed glasses, provided the design of the spectacles.

Lady’s head and teeth
Lady’s head and teeth Image

Technical specifications:

The female mannequin’s head was printed with SLS technology in polypropylene material on a Ricoh AMS5500P. The teeth were printed with MultiJet technology in VisiJet M2 RWT Plastic Material – Rigid White.

 

Technology highlights:

The Ricoh AM S5500P comes with a maximum building envelope from 550 x 550 x 500 (LxBxH/mm) and distinguishes itself with an open parameter system and the ability to process materials at elevated temperatures (up to 210 C°).
For the Family of the Future project it was decided to print the head in Polypropylene material which has never seen elongation properties that can be established with Additive Manufacturing.

 

Information and use cases:

For more than 80 years, Ricoh has been driving innovation and is a leading provider of document management solutions, IT services, commercial and industrial printing, digital cameras and industrial systems. Today, Ricoh is drawing on its heritage and expertise to become a leading innovator is the disruptive arena of Additive Manufacturing.
The AM S5500P machine is available in Europe since November 2015 and immediately found its way to leading Automotive companies such as Daimler and Volkswagen.
RICOH commits to further develop more unique materials for Powder Bed Fusion (Laser Sintering) technology as well as new hardware innovations.

Child mannequin
Full-colour hand
Full-colour hand Image

Technical specifications:

Printed with the PolyJet Matrix technology on the Stratasys® J750 by Seido Systems.

 

Technology highlights:

Polyjet models are smooth beautiful and ready to handle without additional curing or post-processing. By doubling the number of nozzles in the Stratasys J750 printheads an increased throughput is realized in combination with ultra-smooth surfaces and fine details with a layer thickness as fine as 14µm – about half the width of a human skin cell. By loading up to six materials at once, the Polyjet technology is able to produce true, full-color parts with texture mapping and color gradients or producing multi material parts with improved mechanical properties by the use of digital materials.

 

Information and use cases:

If seeing is believing, holding something this real is knowing for sure. The Stratasys J750 delivers unrivaled aesthetic performance to your brightest ideas and boldest ambitions, including true, full-color capability with texture mapping and color gradients. Create prototypes that look, feel and operate like the finished products.

With the capability to blend colored, clear and flexible materials voxel by voxel, the J750 can create multi-material models such as surgical-planning models that save lives, shorten operation time and improve the patient’s recovery. Other applications include prototypes with final-product colour, labels and realism; accurate anatomical models for medical device testing; tools, parts and prototypes in a wide range of colours and material characteristics, all in an easy, streamlined 3D-printing workflow.

Child’s head
Child’s head Image

Technical specifications:
Printed in DSM Somos® Watershed XC 11122 using Stereolithography (SLA) technology.

Technology highlights:
As one of the industry’s most popular materials, Somos® WaterShed XC 11122 is the obvious solution for numerous applications. Whether you’re a designer looking for highly detailed parts with superior clarity and water resistance, or an engineer focusing on durability for functional testing, Somos® WaterShed XC 11122 mimics the look and feel of clear thermoplastics, such as ABS and PBT.

Information and use cases:
Somos® Watershed XC 11122 was used to create a 3D printed inlet manifold that allowed one of the world’s leading automotive engine manufacturers, Rausch Yates Engines, to test the design durability. In addition, the clarity allowed them to see fuel build-up during testing which enables design changes to be made prior final part production. This has provided Rausch Yates with a competitive edge and shortened their development cycle.

Smaller versions of the child
Smaller versions of the child Image

Technical specifications:

Combination of FDM 3D-printing, laser cutting and post-processing.

Technology highlights:

By combining 3D-printing, laser cutting and traditional methods and materials, true freedom of creation is achieved. FDM-printing is a low-cost solution for many applications – in prototyping as well as for useful end-products.

Information and use cases:

Howest conceived a small DIY version of the child of the Family of the Future. Standard off-the-shelf parts and customized items joined together for a fully customized result, but suited to make small series. This results in unlimited creativity and solutions for any challenge.

Modular toy robot
Modular toy robot Image

Technical specifications:

All parts are printed with the FDM technology on a basic home 3D-printer.

Information and use cases:

The parts were designed in such a way that minimal support material would be needed in order to build them properly. Thanks to this design solution, the parts are as good as ready to play with once they are taken off the build platform.
With this we could help children come into contact with 3D-printing in a playful and engaging way.

Personalized shoe lace locks
Personalized shoe lace locks Image

Technical specifications:

Polyamide, dyed and powdershot blasted with a dirt and water resistant coating.

Technology highlights:

This part was created using the fully automated Dimension4 supply chain platform for personalized 3D-printed products. Thanks to the built-in optimization algorithms of the platform, the part was manufactured quickly and very cost effectively (less than 1 euro), with near-zero human intervention. The part itself is made from a strong and flexible polymer (PA2200) that was treated to be water and dirt resistant.
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Information and use cases:

The shoe lock is a product that beautifully demonstrates the potential of 3D-printing for end consumer products. With products like these and an efficient, automated supply chain, online retailers can now easily sell personalized goods. Thanks to 3D-printing, no stock is needed and each product can be made available in different variations without a cost penalty.

Smartwatch casing: frame and back cover
Smartwatch casing: frame and back cover Image

Technical specifications:

The frame was 3D-printed in Titanium and post-processed by Raytech using SLM technology. The back cover was 3D-printed in Resin using SLA technology.

Technology highlights:

The smartwatch configurator runs on Twikit’s engine enabling live customization on any digital platform. The frame is built by Twikit’s advanced parametric product builder where all further customization boundaries are determined. After the configuration is set, the unique 3D file of the watch is automatically generated and linked to Raytech’s production unit where it will be 3D-printed and finished carefully. The combination of the unlimited design variations and the quality of titanium 3D-printing results in a new way of making products.

Information and use cases:

Where smartphones have cases available in different colors and shapes, the smartwatch is limited to the color and material of its casing or wristband. As a smartwatch is a young product, companies are still exploring the customers demands and carefully picking safe combinations of shapes and styles. With Twikit’s parametric customization engine and Raytech’s premium quality metal printing this is about to change. The outer frame, which used to be uniform within different smartwatch brands, can now range from a classic design to a more sportive look, printed with high accuracy in durable and light-weight titanium. The design is adjustable in an intuitive interface, that can easily be implemented in e-commerce platforms or POS applications.

e-NABLE prosthetic hand
e-NABLE prosthetic hand Image

Technical specifications:

Printed using FDM technology in PLA (polylactic acid).

Technology highlights:

Developed collaboratively by people all around the world, the e-NABLE hand is designed with ease of printing and assembly in mind.

Information and use cases:

From two men working together across 10,000 miles to help one child in need – to a global revolution and movement of thousands of digital humanitarians who are helping thousands of others and paying it forward: e-NABLE is a platform for providing 3D-printed hands to children in need. Accessible, cost effective, and colorful. All to improve their life, provide an aide that will give them more flexibility, boost their self-esteem. It is a platform of volunteers, some with medical background, some with a background in 3D design and printing, all with a drive to help people. The wonderful and ever growing e-NABLE Community of volunteers are using their 3D-printers to create free devices for children and adults with upper limb differences.

Soft wearable wristband - interval meter demonstrator
Soft wearable wristband - interval meter demonstrator Image

Technical specifications:

Stencil printing of liquid metal on SMD components embedded in silicone rubber.

Technology highlights:

This wristband showcases a hybrid soft circuit, meaning traditional rigid components were combined with soft conductive paths in a silicone matrix to attain an assembly which is soft and stretchable as a whole. The extraordinary part of this demonstrator lies with the fact that it is a fully embedded device. It encompasses a coin cell (power), logic unit (microprocessor), input (touch pad) and output (indicator led’s). In addition, all components where combined in a single production step.

Information and use cases:

The wristband’s program functions as an interval meter. Its envisioned context is that of a runner who wants to keep a steady pace. These kinds of devices are not new at all. The point of interest lies with its implementation. We already have seen devices which bend (commercial phase) and stretch (research and spin-offs). This device represents the next wave: soft electronics which can be implemented even more conformable to their environment than ever before. It is a fully integrated soft, stretchable device in context of the PhD thesis of Steven Nagels at IMO-IMOMEC. Main applications areas are human-computer interaction, bio sensing and soft robotics.

deltaRocket Pro
deltaRocket Pro Image

Technical specifications:

High-quality FDM-printer according to delta principle with autocalibration. Layer thickness from 80 to 300 micron and positional accuracy from 0.1 mm. Print head with unique magnets suspension.

Technology highlights:

During the development, sustainability (e. g. linear guides), quality (delta principle, autocalibration) and ease of use (e. g. heated bed) were the main parameters taken into account. Hence the choice for a delta FDM printer. The print head is attached by means of solenoids to reduce backlash to a minimum. This also increases the print speed. Due to the heated print bed, several types of material can be used (PLA, ABS, PETG, etc.). Thanks to the autocalibration, the printer is truly plug-and-play, and can be controlled by USB or SD Card.

Information and use cases:

The printer was developed to be durable, user-friendly and of a superior quality. A plug-and-play printer that delivers the desired accurate results every time, with fully automatic calibration for each printout. The open design and reliability makes the printer a perfect fit for educational use as well.

Velleman Vertex Delta
Velleman Vertex Delta Image

Technical specifications:

A low-cost yet high-quality tripod FDM-printer, with a layer resolution of 0.05 mm to 0.2 mm. The printer has a print speed of 20 – 75 mm/s and boasts an automatically calibrated print bed.

Technology highlights:

The Vertex Delta is an all-round and reliable 3D-printer designed to print refined objects for your projects.

Aside from the excellent print quality and user-friendliness, the Vertex Delta also comes with a lot of innovative perks to make your 3D-printing experience more engaging and pleasant. Advanced safety features, a filament run out detector and automatic calibration and bed compensation are only a few of the latest technological additions. This Vertex comes as a hybrid kit which means that after a straightforward and quick assembly, your Delta 3D-printer is ready to serve you.

Information and use cases:

Velleman wanted their Vertex Delta to have a new edge and an acceptable price; aside from the fundamental requirements like the excellent print quality and its reliability, this 3D-printer has a lot of other innovative perks.

Male mannequin
Phits Insoles – custom orthotics
Phits Insoles – custom orthotics Image

Technical specifications:

Printed in PA12 using SLS technology.

Technology highlights:

Phits Insoles are the world’s first and only true translation of personal dynamic gait analysis parameters in a 3D-printed foot orthotic. 3D-printing enables RS Print to incorporate local stiffness and directional stiffness into the core of the orthotic. Too often, 3D-printing is used as a marketing gimmick in orthopedics, Phits insoles goes beyond that point to make mass customization a reality.

Information and use cases:

RS Print was founded in 2014 as a joint venture of Materialise and RSscan. The Phits Insoles brand was launched in 2015. Over 150 Phits experts in 20 countries are already improving thousands of people’s lives with Phits. The Phits experts network consists of podiatrists, orthopedic technicians, fysiotherapists, occupational medicine and specialized retail.

3D-printed knee protection on workwear trousers
3D-printed knee protection on workwear trousers Image

Technical specifications:

Centexbel printed unique knee protectors, designed by Artevelde University College, with TPU filament using FDM-technology onto workwear trousers.

Technology highlights:

By printing directly onto conventionally produced substrates, additional assembly steps can be avoided and unique products can be made. The design of the 3D-printed knee protector can be made person-specific (by body scanning) resulting in optimal comfort for the user. With the selection of the right 3D-printing materials and textiles good results can be obtained in terms of adhesion onto the textile and washing properties.

Information and use cases:

3D-printing directly onto textiles (or other substrates) is a rather new process ready to be introduced into the industry as an additional technology for various applications, e.g. tailormade reinforcements on textiles or specific connector parts. Further assembly steps can be avoided, smart devices can be integrated, other functionalities can be added, etc.

Via 3D-printing every piece can be customized easily. Further research is being conducted to optimize design & process parameters, to enlarge the scope of printable materials and technologies and for an optimal integration into current production processes.

Smart helmet with lattice structure for cushioning effect and auto-localisation
Smart helmet with lattice structure for cushioning effect and auto-localisation Image

Technical specifications:

3D-scanning of human head by Formando; 3D design and topology optimisation by Formando and Materialise; 3D-printed via HP Multi Jet Fusion in PA12 by 3iD.

Technology highlights:

The helmet is designed to perfectly fit the shape of the user’s skull by 3D-scanning and modelling. The inside of the helmet consists of a lattice structure, generated automatically by the Materialise Magics Structures Module and 3-matic Lightweight Structure Module, enabling you to convert a solid 3D model into a lightweight version. A lattice structure can be applied to reduce the weight of the design, or to reinforce it. Other advantages include: saving powder (raw materials), temperature control, design freedom and perfection.

The separated shells around the lattice structure create a cushioning effect, which is energy-absorbent and distributes the impact. Electronics have been built in to localise a person when he or she has fallen. The HP Multi Jet Fusion technology combines high-quality with low-cost production.

Information and use cases:

This is a conceptual helmet that resolves several issues in one go: the shape is custom-made for a comfortable fit; the shock absorption reduces head injuries as much as technically possible; the built-in electronics (with accelerometer and GPS) send an alarm signal to a control room when wearer has fallen. This helmet can be the perfect solution for people suffering from epilepsy or other falling diseases, or for operators working in high-risk environments.

Yuniku, the world’s first vision-centric 3D eyewear
Yuniku, the world’s first vision-centric 3D eyewear Image

Technical specifications:

3D-tailored eyewear is designed entirely around your face and your vision. Regular spectacles can be customized only to a certain degree. The frame and fitting are a given, and the lenses have to be adjusted to suit them. Yuniku, by contrast, uses a revolutionary vision-centric approach. Advanced software calculates the ideal position of the lenses in relation to our eyes, and then 3D-prints the frame accordingly. For the first time, you can enjoy the ultimate in optical precision, without compromising on style or fit.

Technology highlights, information and use cases:

In the highly competitive consumer goods industry, a finish can make all the difference. As more and more companies turn to Additive Manufacturing to make better products, stay ahead of the curve by choosing the best finish for your 3D-printed products. We offer you Materialise Luxura: a premium consumer-grade finish to ensure your product looks and feels like the winner that it is.

The Materialise Luxura finishing degree, available in a range of contemporary colors, is designed to deliver the ideal aesthetic, tactile feel and quality assurance for your product. Choose the finish your product needs to gain the maximum added value.

Pneumatic hand
Pneumatic hand Image

Technical specifications:

The pneumatic hand by Materialise is made up of the palm and wrist area which are printed in polyamide, and the fingers which are printed in flexible TPU by KU Leuven. The hand can grip objects using compressed air. The fingers are designed with an expandable (flexible) side and a non-expandable (rigid) side. When compressed air is applied one side expands and the other stays at the same length. As a result, the finger bends and flexes. The bellows have been designed for optimized flexing and minimized internal stresses. Internal air channels are incorporated into the hand and wrist to distribute the compressed air to the fingers.

Technology highlights:

The potential of the SLS technology was pushed to the limit in this case, in combination with TPU material. A very thin wall thickness of 1.2 mm is necessary to provide the necessary bending range for the fingers while maintaining air tightness. The pneumatic fingers showcase a flexible thermoplastic elastomer made from powder tuned for Laser Sintering and currently not commercially available for this technique. It shows higher stiffness than currently available Laser Sintering rubbers. Its properties are interesting for biomechanical and orthopedic applications.

Information and use cases:

New materials support the evolution of Additive Manufacturing to an established production technique for parts tailored to form and function. 30 years of experience in research and innovations on the combination of materials, hardware and software for Additive Manufacturing at KU Leuven proves to be a good way to change the manufacturing industry. Beyond-state-of-the-art research results in durable collaborations with industry and continuous innovation in AM. This rubber material is only one example of these tangible results. The flexible fingers are mainly used in industrial gripping applications (gripping parts with industrial automation robots in a factory assembly line) but other possible uses of these actuators include consumer-oriented (household) robots.

Made to measure Bantu shoe, based on biomechanical principles
Made to measure Bantu shoe, based on biomechanical principles Image

Technical specifications:

Selective Laser Sintering technology in Polyamide (PA).

Technology highlights:

Handcrafted shoe production and 3D-printing have a lot in common: its use of materials and time and its focus on the individual. After scanning a person’s feet ‘a made to measure’ shoe is printed in specific 3D-printed material. The link with the indigenous counterpart, a Bantu shoe made out of vegetable tanned buffalo hide, is clear both in aesthetics and in biomechanical properties. A full analysis of the indigenous model that served as main inspiration was published and is freely available under DOI:10.1002/ajpa.23169.

Information and use cases:

Future Footwear Foundation stimulates progress in our understanding of human locomotion and sustainable footwear for body and environment. Inspired by the convergence of traditional wisdom and modern technology, the research project Future Footwear 2.0 at KASK School of Arts aims to bring sustainable production and individual needs closer together through 3D-printing.  This concept is materialized by the shown prototypes. The products will be on the market early 2018.

Topology optimized wrench
Topology optimized wrench Image

Technical specifications and technology highlights:

Designed using topology optimization: a method of reducing the weight of a structural part while still maintaining rigid structure. Printed using Laser Metal Deposition technology by LCV in Powder 316L stainless steel.

Information and use cases:

This wrench was designed by a student from Thomas More university college and manufactured by LCV. It shows the possibilities of light weighting a structure with the aid of topology optimization. These complex structures are hard to manufacture with subtractive manufacturing methods such as CNC milling. That’s why LCV is the perfect partner to manufacture these type of products: with their Laser Metal Deposition and cladding technology, they can manufacture large and complex parts. The LCV-Form offers high speed 3D-printing: LCV prints a 500 mm high manifold in less than 3 hours. This opens new possibilities for Near Net Shape (NNS) 3D-printing. Other applications include gears, cutting tools, punching dies, etc.

Customized toolholder and belt
Customized toolholder and belt Image

Technical specifications:

The belt is printed using a low-cost FDM printer with a polyamide filament. The belt is designed to be spiraling, in order to be able to make a longer part. The belts’ flexibility was created by applying a smart, hollow design.
The toolholder was designed to match the 3D-printed wrench. It was printed in PLA on a low-cost FDM printer.

Technology highlights:

Inexpensive and easy accessible 3D-printing technology. Polyamide gives strong, yet flexible products. The material is strong and wear-resistant.

Information and use cases:

Prototype and proof of concept; real applications are quickly built, e.g. for tooling parts, small (non-critical) machine components, etc.

Bionic hand training prosthesis
Bionic hand training prosthesis Image

Technical specifications:

The arm piece was printed in stainless steel using LBM (Laser Beam Melting, often called SLM); the part is built up layer by layer in a powder bed, on a stainless-steel substrate. After removing the powder and substrate, both parts were joined together using TIG welding. The piece was subsequently sandblasted. Most other parts of the arm were printed using FDM technology (Fused Deposition Modeling).

The materials used are ABS, PLA and SS 316L.

Technology highlights:

Myo-electrical prostheses convert potential differences in the muscles to mechanical movements. In the pre-prosthesis phase, exercise prostheses are used in the rehabilitation centre to offer the client a first form of therapy pending final prosthesis. However, this prosthetic hand is not attached to the body. Only in a second phase a preliminary prosthetic socket is made to measure. These sockets, or connections to the body, are therefore expensive and user specific.

As a result, the training prosthesis was always to be held by the client’s other hand or therapist. A specific in field design project was established to improve this period of in the prostheses training for transradial amputations. The result is the’ Actual P’: a universal myoelectric training prosthesis for people with transradial amputation. The prosthesis has a robust look-and-feel, is very light in use and consists of 80% 3D-printed parts. The innovative design, consisting of modular arm segments and an adaptable coupler, ensures a wide range of users.

Information and use cases:

From purely industrial cases up to the personalization of utensils for operators, even if they have a disability: it becomes possible with 3D-printing.

Smart driller
Smart driller Image

Technical specifications:

The drilling machine is truly an end-product (composed of mechanical parts, motors and electronics). More than 90% of the weight of the structure has been 3D-printed in titanium. Connectors are 3D-printed in plastic material. The titanium parts are printed with so-called Electron Beam Melting technology (EBM).

Technology highlights:

The advantage of using titanium 3D-printing is an optimization of the strength to weight ratio, a minimization of the number of parts to assemble, as well as an integration of numerous functions (mechanical and thermal). The specific advantage to use EBM, is to get an accurate part directly from the machine, without a need for thermal treatment. In addition, the productivity is superior to laser, which leads to lower costs.

Information and use cases:

The Smart Driller has demonstrated that 3D-printing allows to design and produce better products, and the capabilities of the Smart Driller for aerospace are superior to any other drilling machine on the market. And it comes at a very competitive price. This smart design and production can be reproduced for other industrial products or tooling. That’s what AMT-Titastar is doing for its customers in various industries.

3D-printed connectors
3D-printed connectors Image

Technical specifications:

Sirris designed all 3D-printed connectors on the Family of the Future skeletons. Prints in PA12 via Selective Laser Sintering (SLS) and other technologies.

Technology highlights:

Design for Additive Manufacturing is still an expert job; Sirris fully masters this expertise and offers individual support at every step along the way, from the drawing board stage right through to prototype development and pilot tests for finished products.

SLS-printed components are strong and of very high quality. This technology is also very suitable for producing both small and larger series. As no support structures are required, a large complexity of the components can be obtained.

Information and use cases:

The combination of 3D-printing and standard parts: an efficient and modular solution that changes the way fixtures are designed and manufactured, and offers a high degree of customization and accuracy, applicable in many industries.

Female mannequin
Cock-up splint Image
Cock-up splint
Technical specifications: Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated. Technology highlights: 3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company?... Lees meer
Rescue-corset Image
Rescue-corset
Technical specifications: Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated. Technology highlights: 3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company?... Lees meer
Prosthetic sleeve Image
Prosthetic sleeve
Technical specifications: Printed with HP Multi Jet Fusion (MJF) technology in PA12, coated. Technology highlights: 3D-Printing allows Aqtor! to produce customized products (which accounts for 85% of the company?... Lees meer
Cranioplasty implant Image
Cranioplasty implant
Technical specifications: Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM).   Technology highlights: The PEEK cranioplasty implant serves to protect the patient’s brain ... Lees meer
Total temporomandibular joint prosthesis Image
Total temporomandibular joint prosthesis
Technical specifications: Surgical grade PEEK and titanium, printed using Selective Laser Melting (SLM). Technology highlights: The total TMJ (temporomandibular- or jaw joint) prosthes... Lees meer
Spinal column vertebrae Image
Spinal column vertebrae
Technical specifications: Printed in DSM Somos® Watershed XC 11122 using Stereolithography (SLA) technology. Technology highlights: As one of the industry’s most popular materials, ... Lees meer
Anatomical heart Image
Anatomical heart
Technical specifications: Printed using SLS technology in PA2200. SLS-printing is very suitable for producing both small and larger series. As no support structures are required, a large complexity of the components can be obtai... Lees meer
Hip implant Image
Hip implant
Technical specifications: Printed at ESMA with SLM technology in Ti64 on a Renishaw AM250. Heat-treated through Hot Isostatic Pressing (HIP) at Bodycote HIP.   Technology highlights: Where initially c... Lees meer
Temporary Crown & Bridge (teeth) Image
Temporary Crown & Bridge (teeth)
Technical specifications: Printed with light-curing composite for temporary crown and bridge using SLA technology. Technology highlights: In order to serve the demand in the dental market, GC sta... Lees meer
Lower leg Image
Lower leg
Technical specifications: Laser metal deposition (‘laser cladding’) technology with 316L stainless steel powder. Technology highlights: The LCV-Form benefits are design freedom, fast delivery, and high speed ... Lees meer
Ceramic inteverbral Image
Ceramic inteverbral
Technical specifications: Silicon carbide intervertebral printed using SLS technology.   Technology highlights: Via Selective Laser Sintering, small silicon and silicon carbide powder particles can be ... Lees meer
Insole with pressure monitoring Image
Insole with pressure monitoring
Technical specifications: Printed using Filament Deposition Modeling (FDM): a low-cost technology offering solutions for high-end challenges. Technology highlights: Embedded pressure sensors continuously monitor ... Lees meer
Fully 3D-printed glasses Image
Fully 3D-printed glasses
Technical specifications: The eyewear frame was printed in titanium (TiAl6V4) using DMLS – powder bed technology. The lenses were printed in E-Shell 600 biocompatible material. Technology highlights, information and us... Lees meer
Lady’s head and teeth Image
Lady’s head and teeth
Technical specifications: The female mannequin’s head was printed with SLS technology in polypropylene material on a Ricoh AMS5500P. The teeth were printed with MultiJet technology in VisiJet M2 RWT Plastic Material – Rigid ... Lees meer
Child mannequin
Full-colour hand Image
Full-colour hand
Technical specifications: Printed with the PolyJet Matrix technology on the Stratasys® J750 by Seido Systems.   Technology highlights: Polyjet models are smooth beautiful and ready to handle without ... Lees meer
Child’s head Image
Child’s head
Technical specifications: Printed in DSM Somos® Watershed XC 11122 using Stereolithography (SLA) technology. Technology highlights: As one of the industry’s most popular materials, ... Lees meer
Smaller versions of the child Image
Smaller versions of the child
Technical specifications: Combination of FDM 3D-printing, laser cutting and post-processing. Technology highlights: By combining 3D-printing, laser cutting and traditional methods and materials, true freedom of c... Lees meer
Modular toy robot Image
Modular toy robot
Technical specifications: All parts are printed with the FDM technology on a basic home 3D-printer. Information and use cases: The parts were designed in such a way that minimal support material would be needed i... Lees meer
Personalized shoe lace locks Image
Personalized shoe lace locks
Technical specifications: Polyamide, dyed and powdershot blasted with a dirt and water resistant coating. Technology highlights: This part was created using the fully automated Dimension4 supply chain platform fo... Lees meer
Smartwatch casing: frame and back cover Image
Smartwatch casing: frame and back cover
Technical specifications: The frame was 3D-printed in Titanium and post-processed by Raytech using SLM technology. The back cover was 3D-printed in Resin using SLA technology. Technology highlights: The smartwatc... Lees meer
e-NABLE prosthetic hand Image
e-NABLE prosthetic hand
Technical specifications: Printed using FDM technology in PLA (polylactic acid). Technology highlights: Developed collaboratively by people all around the world, the e-NABLE hand is designed with ease of printing... Lees meer
Soft wearable wristband - interval meter demonstrator Image
Soft wearable wristband - interval meter demonstrator
Technical specifications: Stencil printing of liquid metal on SMD components embedded in silicone rubber. Technology highlights: This wristband showcases a hybrid soft circuit, meaning traditional rigid component... Lees meer
deltaRocket Pro Image
deltaRocket Pro
Technical specifications: High-quality FDM-printer according to delta principle with autocalibration. Layer thickness from 80 to 300 micron and positional accuracy from 0.1 mm. Print head with unique magnets suspension. ... Lees meer
Velleman Vertex Delta Image
Velleman Vertex Delta
Technical specifications: A low-cost yet high-quality tripod FDM-printer, with a layer resolution of 0.05 mm to 0.2 mm. The printer has a print speed of 20 – 75 mm/s and boasts an automatically calibrated print bed. Te... Lees meer
Male mannequin
Phits Insoles – custom orthotics Image
Phits Insoles – custom orthotics
Technical specifications: Printed in PA12 using SLS technology. Technology highlights: Phits Insoles are the world’s first and only true translation of personal dynamic gait analysis parameters in a 3D-printed ... Lees meer
3D-printed knee protection on workwear trousers Image
3D-printed knee protection on workwear trousers
Technical specifications: Centexbel printed unique knee protectors, designed by Artevelde University College, with TPU filament using FDM-technology onto workwear trousers. Technology highlights: By printing dire... Lees meer
Smart helmet with lattice structure for cushioning effect and auto-localisation Image
Smart helmet with lattice structure for cushioning effect and auto-localisation
Technical specifications: 3D-scanning of human head by Formando; 3D design and topology optimisation by Formando and Materialise; 3D-printed via HP Multi Jet Fusion in PA12 by 3iD. Technology highlights: The helm... Lees meer
Yuniku, the world’s first vision-centric 3D eyewear Image
Yuniku, the world’s first vision-centric 3D eyewear
Technical specifications: 3D-tailored eyewear is designed entirely around your face and your vision. Regular spectacles can be customized only to a certain degree. The frame and fitting are a given, and the lenses have to be adj... Lees meer
Pneumatic hand Image
Pneumatic hand
Technical specifications: The pneumatic hand by Materialise is made up of the palm and wrist area which are printed in polyamide, and the fingers which are printed in flexible TPU by KU Leuven. The hand can grip objects using co... Lees meer
Made to measure Bantu shoe, based on biomechanical principles Image
Made to measure Bantu shoe, based on biomechanical principles
Technical specifications: Selective Laser Sintering technology in Polyamide (PA). Technology highlights: Handcrafted shoe production and 3D-printing have a lot in common: its use of materials and time and its foc... Lees meer
Topology optimized wrench Image
Topology optimized wrench
Technical specifications and technology highlights: Designed using topology optimization: a method of reducing the weight of a structural part while still maintaining rigid structure. Printed using Laser Metal Deposition technol... Lees meer
Customized toolholder and belt Image
Customized toolholder and belt
Technical specifications: The belt is printed using a low-cost FDM printer with a polyamide filament. The belt is designed to be spiraling, in order to be able to make a longer part. The belts’ flexibility was created by apply... Lees meer
Bionic hand training prosthesis Image
Bionic hand training prosthesis
Technical specifications: The arm piece was printed in stainless steel using LBM (Laser Beam Melting, often called SLM); the part is built up layer by layer in a powder bed, on a stainless-steel substrate. After removing the pow... Lees meer
Smart driller Image
Smart driller
Technical specifications: The drilling machine is truly an end-product (composed of mechanical parts, motors and electronics). More than 90% of the weight of the structure has been 3D-printed in titanium. Connectors are 3D-print... Lees meer
3D-printed connectors Image
3D-printed connectors
Technical specifications: Sirris designed all 3D-printed connectors on the Family of the Future skeletons. Prints in PA12 via Selective Laser Sintering (SLS) and other technologies. Technology highlights: Design ... Lees meer