Materialise S.A.

Materialise S.A. is the first comprehensive prototyping centre in Poland, specialising in the production of fully functional prototypes. We focus on solving our customers' problems. Our advisers work to achieve the set objectives and to continuously improve results. We aim to ensure that the results of our work always fully meet the needs and requirements of each customer. The first step towards full customer satisfaction is understanding the customer's expectations; for this reason, we consult with each potential customer before a project is started. This allows us to select the most suitable rapid prototyping methods and solutions. We use a wide range of rapid prototyping techniques, i.e. the production of prototypes and small production series by means of additive manufacturing technologies (3D printing). Depending on the target product, we can apply the optimal method that gives the most accurate representation of the finished product at the lowest possible production cost. The RP techniques we use are:SLA (Stereolithography) – cross-sections are traced on the surface of a liquid polymer, which is solidified by a laser beam. This is currently one of the most widely used rapid prototyping technologies for producing plastic models. It is used to produce parts with smooth surfaces, fine details and complex geometries, components coated in a metallisation process, and parts for market testing. One of the main advantages of this technology is the use of unique Stereolithography Mammoth machines, with build chambers measuring 2100x680x800 mm, which allow large single-piece parts to be printed in very high quality. SLS (Selective Laser Sintering) – selective sintering of powders is an additive method used to produce fully functional, high-strength and homogeneous prototypes from PA 12 thermoplastic materials, which offer very good mechanical properties and high temperature resistance up to 130°C. For more detailed information, please visit our website www.e-manufacturing.pl. FDM (Fused Deposition Modeling) – modelling with molten thermoplastic material along the Z axis, in layers from 0.1 mm to 0.33 mm, with an accuracy of 0.15 mm. The basic thermoplastic material used for FDM prototypes is ABS-M30, which has mechanical properties suitable for engineering applications, resistance to water and chemicals, and temperature resistance up to 85°C. Polyjet – in this technology, the prototype is built on a special tray above which print heads dispense the build material. The heads move along the X axis, as in a conventional printer, depositing a single, very thin layer of photopolymer. Each layer of resin is cured with UV light immediately after it is applied. As a result, no additional post-processing (curing, soaking, etc.) is required, unlike in other technologies. After printing, the support material is removed from the finished part. DMLS (Direct Metal Laser Sintering) – DMLS, the direct fusion of metal powders, is the most recent additive technique, allowing products to be made in metal materials directly from 3D CAD data. Products can be made from various materials, such as 1.2709 tool steel, 1.4542 stainless steel, AlSi10Mg aluminium and, since September 2015, TiAl6V4 titanium. The technology allows very precise prototype models to be produced from these materials, as well as fully functional, durable products such as tools or injection mould components, including components with conformal cooling channels. The main advantage of DMLS is that channels can be routed freely inside the mould, which allows more effective mould temperature control and more efficient cooling. This is possible because the mould is built layer by layer – the laser beam sinters only those areas that are to be joined to the previously applied layer. This build process ensures that the channels run at an equal distance from the mould surface, which allows uniform stabilisation of the mould temperature. VC (Vacuum Casting) – vacuum casting in silicone moulds. This technology is used for short production runs of 25–50 pieces. A wide range of polyurethanes makes it possible to select a material with physical properties similar to those of the thermoplastics intended for the final product. CNC – we also produce short production runs in metals (aluminium, brass, bronze, steel) and in engineering plastics (PE, PTFE) using our advanced technical facilities. FUSION 3000 – we also offer a surface smoothing technology, unique worldwide, for models made using FDM and SLS. With this technology, the models are smoothed and their surface becomes smooth and glossy. The visible porosity and surface irregularities typical of prototyping techniques disappear. The surface finish becomes similar to that of parts produced by plastic injection moulding. Models treated in this way have much greater flexibility. The process also makes the models completely leak-tight and resistant to liquids and gases. The process significantly reduces surface roughness. 3D scanning – 3D scanning allows us to obtain a digital model of an existing part (reverse engineering technology). Based on the resulting 3D digital model, we can carry out any editing and modification of the model and then produce a copy of the scanned part using additive technologies. In addition, our 3D measurement and scanning laboratory is equipped with the mobile TRITOP system for optical measurement of objects up to 20 m in size, which determines the position of points and visible features of parts with high accuracy in a very short time. Reverse engineering – the process of examining a product to determine exactly how it works, as well as how it was made and at what cost. It is usually carried out to obtain the information needed to design an equivalent product. Another application is comparison with, or ensuring compatibility with, one's own products.