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3D Systems Top 10 applications over the past year


3D Innovation: The Top Ten Applications in 2016 (in reverse order):-

10. Craft

For nearly 50 years, Polich Tallix Fine Art Foundry has helped artists develop and produce their work. Using a complete digital workflow that combines 3D scanning with Geomagic software and wax 3D printing, Polich Tallix’s digital production department helps its clients deliver art exactly as envisioned. According to the foundry’s 3D Artist and Production specialist, these solutions have helped Polich Tallix extend its capabilities beyond what anyone thought possible.


9. Autonomy

After seven decades of relying on external suppliers, Hyde Park Partners decided to take product development applications into its own hands with in-house 3D printing on the ProJet® MJP 2500. Now able to implement new ideas and designs faster without the cost and delay of contracted work, Hyde Park is more nimble and effective in its day-to-day operations.


8. Ingenuity

While there’s no denying the uniqueness of a live performance, Intel and Lady Gaga took things to the next level at this year’s 58th Grammy Awards. Facilitated by the on-demand manufacturing expertise and digital artistry of our Gentle Giant Studios entertainment specialists, Lady Gaga’s tribute to David Bowie was full of the inventiveness and creativity of the team that conceptualized it and the man it honored, with a supporting role by 3D scanning and 3D printing.

7. Inspiration

The members of the University of Connecticut’s Formula SAE team showed incredible initiative in the making of their most recent racecar. Realizing that they could dramatically impact the weight, lines and performance of their car by designing the body around the engine, rather than accommodating the engine after the fact, they turned to Bolton Works, a local reverse engineering specialist, to help them with their task. Using a suite of Geomagic scan-to-CAD software, the team devised a perfect on-screen replica of their engine to tailor their car like never before.

6. Efficiency

In collaboration with Oak Ridge National Laboratory, the University of Maryland’s Center for Environmental Energy Engineering (CEEE) is on a quest to develop next generation heat exchangers for HVAC and refrigeration applications. Using automated design algorithms for optimal thermal resistance at a reduced size and weight, CEEE produced a 1kW heat exchanger that was 20% more efficient, in addition to being lighter and smaller. CEEE was also able to reduce the manufacturing cycle from months to weeks with the help of our on demand manufacturing service and direct metal printing.

5. Healing

Following multiple spinal fusion surgeries after a fall from construction left him partially paralyzed, Mark Weimer began to experience consistent lower body pain alongside bowel and bladder issues. To help alleviate the compression of Weimer’s nerves and spinal cord, Dr. George Frey designed his surgical approach with digitization and manufacturing services provided by 3D Systems Healthcare and his patented FIREFLY® Technology for pedicle screw placement. Equipped with 3D printed anatomical models and surgical guides specific to Weimer’s anatomy, Dr. Frey performed a 15-hour surgery that returned Weimer’s attention to more important things like his grandsons’ budding passions for hockey.


4. The Little Guys

The ability to customize solutions means no problem is too big or too small to fix. In the case of Grecia the Toucan and Yellow-Purple (AKA “Purps”) the penguin, this was good news in 2016. Using an array of 3D design and manufacturing technologies, the team of veterinarians and communities of animal lovers behind these birds had ample reason to whistle a happy tune.


3. Productivity

Conformal cooling in mold design enables vast improvements in overall cycle time and cost, but remains relatively underutilized due to the design and manufacturing hurdles that accompany the technique. Bastech tackled these problems with a streamlined workflow of digital design and manufacturing solutions. Using Cimatron™ software for accelerated mold design, direct metal printing on the ProX® DMP 320 and inspection with Geomagic® Control™, Bastech reduced design time by 70%, cut costs by 16% and shrank cycle time by 14% to set a new standard in productivity.


2. Digital Molding

2016 saw the laying of considerable groundwork towards Digital Molding. Whereas traditional injection molding requires substantial time and material investment before a product can be realized, Digital Molding is changing the manufacturing equation. Powered by our Figure 4 technology, Digital Molding delivers tool-free plastic parts with exceptional efficiency, design flexibility and economics. This ultra-fast, automated stereolithography (SLA) system enables manufacturers to go straight from CAD to manufacturing to go to market faster.



1. Tomorrow

Grace Kablaenga was born with rare and severe facial cleft deformities, extreme distance between her eyes, and no bone separating her brain from her oral cavity.  Due to the physical difficulty of swallowing, she soon suffered from undernourishment and anemia, leading her childhood to be anything but carefree. Fortunately, Grace’s condition came to the attention of the World Craniofacial Foundation, and a team of doctors intervened to solve the anatomical puzzle of Grace’s condition with the help of VSP and 3D printed surgical guides.

Omni large format 3D printer case studies


Two great case studies showing the capabilities of the Omni Factory 2.0 3D Printer.

Prototyping of car parts for Arrinera Automotive S.A.

Racing car producer – Arrinera Automotive S.A. – was looking for an optimum solution to produce car-part prototypes. The engineering process requires the continuous improvement of elements. Creating prototypes with previous production methods extended the time needed and involved high costs.

The company commissioned the printing of auto parts to OMNI3D Printroom. Parts are printed
on a 3D printer – Factory 2.0 Production System using ABS, ASA, PC-ABS, PET-G, HIPS filaments depending
on the requirements. List of all available filaments is available here.

Here is what our client says about the results:

“OMNI3D services significantly accelerate the work of our R&D team. 3D printed parts meet all of our requirements – both in terms of strength, dimensional accuracy and turnaround time.”

Łukasz Tomkiewicz, Managing Director, Arrinera Automotive S.A.

Thanks to the additive technology, we realized the Arrinera’s target – to shorten the process of obtaining the final part. Detail production on a 3D printer reduces production time and costs. Frequent changes of a model’s shape – the diameter or length – are not as problematic as they used to be. A new model can be printed in just over a dozen hours.


Chair seat design

One of our customers were looking for a low cost solution, which would enable to produce a chair seat prototype in the full scale. The most important thing, apart from the size, was the durability and the perfect shape of the model. The customer’s main objective was to specify the ergonomics of the furniture before mass production.

“The 3D printer – Factory 2.0 Production System allows large-format printing. Thanks to OMNI3D solution, we can analyse the ergonomics of models that were printed in a full scale. It’s very important in our sector.”


What we did?

Printroom by OMNI3D printed out couple of chair seat prototypes. Our machine – Factory 2.0 meets two main requirements, which were essential for this project:

  • a working surface of 500 mm in each axis (the chair size is 450 mm x 430 mm x 465 mm),
  • the ability to print with support structures  (two extruders). Generated support structures were necessary to copy the geometry of the 3D model in the proper way. Two materials were used in this project – ABS-42 (main material) and HIPS-20 (supporting material).

List of OMNI3D filaments is available here.

What was the effect?

Thanks to printing the model in its full scale and retaining its durability, designers could test ergonomics of the chair and prepare the best possible design the final furniture. What’s more, using 3D technology to produce a prototype involves low costs.

ZMorph Multi-tool 3D Printer


Article written by Corey Clark on, noting Corey has a keen interest in 3D printing and all tech-related news, as well as the wider impact of additive manufacturing.

ZMorph Dual Pro Extruder opens up new possibilities for 3D printing

ZMorph Dual Pro Extruder opens up new possibilities for 3D printing

ZMorph upgraded its two-material extruder, which now offers four novel options for 3D printing, and one not seen before on the market. The Dual Pro Plastic Extruder can 3D print with two materials using only a single nozzle, opening up exciting possibilities regarding dual materials, color mixing, image mapping and water soluble supports.

The Dual Pro is one of six interchangeable extruders for the ZMorph 2.0 SX multitool 3D printer, that includes a milling tool, laser toolhead, and other extruders for varying material thickness. Supported by updates to ZMorph’s original Voxelizer software, and quite different to anything else currently on the market, we take a closer look at the different ways ZMorph’s most powerful tool to date can be used.

 The ZMorph 2.0 SX multitool 3D printer. Image via ZMorph.

The ZMorph 2.0 SX multitool 3D printer.

One nozzle instead of two

While there are desktop 3D printers that can use multiple materials in the same print run, these often rely upon two nozzles rather than one. The novel approach taken by ZMorph means that users can now work with shaded colours and also map images onto their prints, to create unique and dazzling 3D prints that aren’t typically seen from a desktop 3D printer.

An example of ZMorph's colour shading print. Image via ZMorph.

An example of ZMorph’s colour shading print.

Colour Mixing

The shaded prints are particularly impressive as the technique creates the impression of added depth on a print (as shown above). The prints are made possible by ZMorph’s Voxelizer software and a mixer in the toolhead that blends the two different coloured filaments. Voxelizer allows the user to select which part of the design should be a certain color or shade, and the printer does the rest. The Voxelizer software can also be used to preview prints without needing to generate G-code.

An object being printed with image mapping. Image via ZMorph.

An object being printed with image mapping.

Image Mapping

Another possibility with ZMorph’s technology is that images can be printed directly onto a 3D design pixel-by-pixel. This be done using any .jpeg, photograph or graphical pattern, as shown in the photo above.

Printing PLA and PVA together

The Dual Pro's capabilities of printing PLA and PVA support together. Image via ZMorph.

Furthermore, the Dual Pro Plastic Extruder can print both PLA and water-soluble PVA for supports. This means a design can be printed with soluble supports that can be washed away with water, eliminating some of the laborious post-processing found in FFF prints. Additional geometric complexity is also possible with multi-materials, which can be seen in the video below.

Geomagic training course schedule 2017


2017 Geomagic software training schedule: Week 2 - Wrap; Week 4 - Control X; Week 6 - Design X or Geomagic for SolidWorks. Course length Wrap - 2 days; SW - 3 days; DX - 4 days; CX - 2 days; Sculpt - 2 days. Fast track course is always an option - standard course minus 1 day - usually for users with some prior experience. Courses will generally only go ahead with at least two attendees. Price is per delegate per day, inc. lunch & training notesplus VAT. Please email to express interest.

3DXpert software for Direct Metal Printing


Advanced new software, 3DXpert is dedicated to Metal Additive Manufacturing processes.

Metal Additive Manufacturing has unique requirements that are very different from 3D Printing of plastics and other materials. 3DXpert™ was specifically created to meet the specific challenges of Metal Additive Manufacturing. It will help you easily prepare and optimize parts for metal printing and will enable you to print quality parts in record time. 3DXpert provides the ideal mix of tools for automating repetitive tasks while allowing you full control.

A Single Integrated Solution for the Entire Process

There is no longer a need for several different solutions to get the job done. 3DXpert is a single, integrated solution that offers everything you need – importing part data, optimizing geometry and lattice creation, calculating scan-paths, arranging the build platform, sending it to the printer, and even machining the final product when required.

Greater Agility, Quality, and Speed

3DXpert allows you to seamlessly work with any Geometry for both B-rep (boundary representation, meaning solid or surfaces) and mesh triangulation formats (e.g. STL). This capability eliminates the need to convert solid or surface data into mesh, improving data quality and integrity, saving valuable time, and offering greater flexibility to make changes to the model at any stage of the process, using history based parametric CAD tools.

Shorten Print Time and Ensure Quality

Optimize print strategies for different zones and automatically fuse them into a single scan-path to minimize print time while maintaining part integrity. 3DXpert’s unique and diverse printing strategies take into account design intent and part geometry to create an effective scan-path that addresses the challenges of 3D Metal Printing.


3DXpert Work Process
Use an integrated solution to address all your metal 3D printing needs
Prepare and optimize parts for printing, quickly and easily
Print quality parts in record time
Import Data Position Geometry Optimize Structure Design Supports Set Printing Strategies Calculate Scan-path Arrange Build Platform and Print Perform Post-printing Operation

Import Data
Import Data
  • Import data from all CAD formats (B-rep, DXF, IGES, STEP, VDA, Parasolid (including binary), SAT (ACIS), STL and SAB), native read formats including PMI data (such as AutoCAD, Autodesk Inventor, CATIA, Creo Elements/Pro, Siemens NX, SolidWorks and SolidEdge) as well as virtually all Mesh formats.
  • Take advantage of continued work with B-rep data (solids and surfaces). Reading B-rep geometry without downgrading to mesh maintains data integrity including analytic geometry, part topology and color coding. This allows preparing the part for printing using history based parametric features.
  • Start working immediately with automated healing of both STL and B-rep geometry.

Position Geometry
Position Geometry
  • Position parts on the printer tray, with visualization of gas flow and Recoater/Roller directions.
  • Set part orientation with real-time analysis of support and down-facing areas. Automated orientation optimization allows keeping tray area and supports to the minimum necessary.
  • Apply scaling to compensate for part shrinkage during the build.
  • Use a rich set of parametric and history-based hybrid (b-rep and mesh) CAD tools as well as advanced direct modeling tools to improve part printability and for post-build operations (e.g., close holes and add material for machining, modify geometry due to printability constraints).

Optimize Structure
Optimize Structure
  • Use Micro Lattice to save weight and material. A groundbreaking volume representation technology (V-Rep) allows for lightning-fast creation, editing, and visual manipulation of micro lattices, seamlessly combining the power of lattice structures with history-based parametric features.
  • Optimize lattice structures by creating radial lattices to better fit circular parts, defining your own lattice cell structures, and applying variable lattice thickness based on FEA stress analysis.
  • Import lattice structures designed by other systems.
  • Apply surface lattice to medical parts using V-Rep technology. Add volumetric texture to the outer shell of implants and other medical models to create the required porosity.
  • Hollow out parts using infills to reduce weight and material. Sweep based on a broad 2D pattern library to form internal walls within the part.
  • Use a full set of CAD tools to mend the part (e.g. offset surfaces or holes size) and adjust it to the selected printer if required.

Design Supports
Design Supports
  • Analyze the part to find regions that require supports, or manually define regions.
  • Easily create supports of any type (wall, lattice, solid, cone and skirt supports). Use a rich tool set to fragmentize, tilt, and offset supports to simplify their removal and minimize material requirements.
  • Define, save, and reuse your own templates for automating the creation of supports that fit your needs. Use higher level meta-templates to automate support creation for the entire part with just a single click.
  • Eliminate the need to use supports in hard to reach areas. Define special printing strategies to ensure printing integrity without building supports.
  • Perform quick analysis to identify areas with potential stress and adjust supports design to prevent part distortion.

Optimize Printing
Optimize Printing Strategies
  • Use Zoning technology to apply various print strategies to different areas of the part – reducing printing time and improving surface quality.
  • Accelerate printing time with automated assignment of optimal print strategies to relevant objects (supports, lattices, etc.). Manually assign faster print strategies to internal volumes or zones that do not require high surface quality.
  • Achieve better surface quality by assigning more accurate printing strategies to specific zones (e.g., small features, high surface quality, circular areas).
  • Eliminate the need to divide the part into separate objects and avoid weak spots and lines – using automated fusion of zones with different print strategies to maintain part integrity.

Calculate Scan
Calculate Scan-path
  • Enjoy intelligent scan path calculation based on a combination of zoning and part geometry.
  • Validate the print process with a quick and accurate preview of the actual scan path for selected slices prior to fully calculating the entire part.
  • Use the Scan Path Viewer to review the calculated contours and hatches.
  • Shorten calculation time by offloading and distributing the calculation to additional computers.
  • Get the most out of your printer using pre-defined best practice parameters for each machine, material, and print strategy, or develop your own printing strategies with unprecedented control over scan path calculation methods and parameters.

Arrange Build Platform & Print
  • Position the parts to be printed in any desired array on the build platform and combine all of their scan paths.
  • Use a range of analysis tools to ensure all parts are ready for printing, enabling you to view the combined scan path and estimate print time, material consumption, and overall costs.
  • Finally, send the optimal combined scan path to your printer.

Perform Operations
Perform Post-printing Operations
  • Use robust machining and drilling programing tools to remove supports, machine high-quality surface areas, and drill, tap or rim holes.
  • Enjoy the benefits of using a single system by automatically receiving printing preparation data as stock (including support geometry, support region contours, and machining offset objects), and apply smart machining templates to them.

3D System Ecosystem


3D Systems Ecosystem

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