Materialise 3-matic 11.

Tutorial
 Materialise 3-matic 1

Content
Introduction to 3-matic ................................................................................................................ 3
Video Tutorials for 3-matic ......................................................................................................... 4
1 Exercise 1: Clean up a topology optimized model ............................................................. 5
1.1. Introduction to interface and visualization ................................................................... 5
1.2. Surface manipulations of raw topology data ............................................................... 9
1.3. Redesign CAD-like entities........................................................................................ 15
1.4. Towards FEA ............................................................................................................. 16
1.5. Towards CAD ............................................................................................................ 18
2 Exercise 2: Design changes and labeling ........................................................................ 20
2.1. Introduction to forward engineering........................................................................... 20
2.2. Required material ...................................................................................................... 20
2.3. Design changes ......................................................................................................... 20
2.4. Labeling ..................................................................................................................... 29
3 Exercise 3: Point cloud to STL ......................................................................................... 33
3.1. Introduction to point cloud module ............................................................................ 33
3.2. Required material ...................................................................................................... 33
3.3. Point cloud meshing .................................................................................................. 33
3.4. Scan fixing ................................................................................................................. 34
4 Exercise 4: Reverse engineering...................................................................................... 36
4.1. Introduction to CAD link module ................................................................................ 36
4.2. Required material ...................................................................................................... 36
4.3. Preparation of the STL .............................................................................................. 37
4.4. Reverse engineering ................................................................................................. 38
4.5. Result ......................................................................................................................... 39
5 Exercise 5: Conformal cooling channel design ................................................................ 40
5.1. Introduction to tooling module ................................................................................... 40
5.2. Required material ...................................................................................................... 40
5.3. Creation of centerlines for conformal cooling channels ............................................ 40
5.4. Creation of conformal cooling channels in cavity...................................................... 47
6 Exercise 6: Create a texture ............................................................................................. 48
6.1. Introduction to the Texturing module......................................................................... 48
6.2. Required material ...................................................................................................... 48
6.3. Create a surface for texturing .................................................................................... 49
6.4. Create a 3D texture ................................................................................................... 53
7 Exercise 7: Design a 3D pattern ....................................................................................... 55
7.1. Introduction to the Patterning module ....................................................................... 55
7.2. Required material ...................................................................................................... 55

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7.3. Create a 2D Linear Pattern ....................................................................................... 56

7.4. Create a 3D pattern ................................................................................................... 58
7.5. Merge all parts ........................................................................................................... 74
8 Exercise 8: Design a perforation ...................................................................................... 75
8.1. Required material ...................................................................................................... 75
8.2. Create a 2D Pattern ................................................................................................... 75
8.3. Make a perforation ..................................................................................................... 77
9 Exercise 9: How to make a randomized structure ........................................................... 79
9.1. Required Material: ..................................................................................................... 79
9.2. Create Unit Graph ..................................................................................................... 79
9.3. Remove open edges (optional) ................................................................................. 83
9.4. Assign thickness ........................................................................................................ 84
9.5. Graph to STL ............................................................................................................. 85
9.6. Measure porosity ....................................................................................................... 86
10 Exercise 10: Design a lightweight structure.................................................................. 87
10.1. Required material ................................................................................................... 87
10.2. Create Quad Graph ............................................................................................... 88
10.3. Create Unit graph................................................................................................... 90
10.4. Make connections .................................................................................................. 91
10.5. Prepare graphs ...................................................................................................... 93

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Introduction to 3-matic
This tutorial is designed to introduce the first-time user to the basics of 3-matic. It provides you
with a practical exercise in the post-processing of a topology optimized part to illustrate the
possibilities of 3-matic. In this tutorial, a topology optimized mesh, provided by the TU Delft,
will be re-modeled and brought back to:
 A volume mesh for FEA analysis
 A CAD part with .iges or .step surfaces

3-matic will make sure that all the required tools are available to not only smoothen the
roughened STL file, but also to use CAD-like design features (such as sketches / sweep /
extrude / loft / …) to generate the desired result.

 Reduce your time in CAD packages by avoiding drawing your optimized part from scratch
 Quickly analyze design changes in FEA packages by staying on a meshed design. Get access
to the fastest way from topology optimization to a real AM produced parts, since CAD models
are not required for Additive Manufacturing (AM).

Data flow for topology optimization, where 3-matic can play a central role to interpret your model in a CAD
package, export your mesh towards FEA or immediately towards Additive Manufacturing.

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Video Tutorials for 3-matic

There are multiple video tutorial of 3-matic. They provide you with visualization of various steps
via combination of presentation and demonstration.

These are accessible via Materialise website at 3-matic product home page.
[Link]

These videos are located under various modules of the product. For instance, the Lightweight
Structures Module contains link to all video tutorials related to the Lightweights Module:

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1 Exercise 1: Clean up a topology optimized model

1.1. Introduction to interface and visualization
First, we will explain how the interface of 3-matic is structured and where the different
functions can be found.

Interface
Open the GE Bracket benchmark (.mxp) project
 Operations Toolbar (1) contains the different functions to modify the STL model.
 The View Toolbar (2) can be used to import, save or change the visualizations
of the models.
 The Object Tree (3) contains the parts with their surface structure.
 The Properties Tab (4) contains three options.
i. Operations: In Operations the parameters for each operation can be
filled in.
ii. Macros: A sequence of operations can be recorded in a macro to repeat
multiple parts in a semi-automated way.
iii. Properties: Some statistics of a part, surface, texture or any other entity
can be viewed in the Properties Tab.

2
3

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Object Tree and entities

The Object Tree provides a structured overview of the parts that are currently open in 3-
matic.

Object Tree: Section view:

Look inside your design by using a section
on your part. The red zones are the solid
areas of your part.
The position of the section can be
changed in the Properties Tab (bottom
right). To hide one side, one can activate
the clip function.

Part information :
Each part can contain multiple entities,
going from:
 A part specific coordinate system,
 Surfaces that make up the model
 Curves that can be mapped to split
surfaces or can be used in CAD-like
operations.
 And many more…

In the tutorial project, two parts are given, the Design Space (originally a CAD file) and the
optimized meshed part. By inspecting the surface structure of each part, you may notice an
important difference between the two files.

1. Transparency: the Design Space is visualized as transparent. To change the transparency

a. Click with the right mouse button on the part in the Object Tree
b. Go to Transparency > Opaque

2. Hide: to hide the topology optimized mesh

a. Click with the right mouse button on the part name in the Object Tree
b. Click on Hide

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Change transparency of a part Hide a part

Design space (from CAD)

The Design Space is a CAD file that has been converted to STL, keeping the same structure
as in the original CAD package. The surface list gives an overview of the different surfaces as
your part contains many different surfaces. Surfaces can also be selected by clicking on them
in the working area.

Clicking in the middle of a surface, you can select the entire part Clicking on a contour, you can select the contour of a surface, a
or only the selected surface specific surface fin or a manually defined part of the contour

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Raw topology data

The raw topology data consists of one big surface, without any splits. In chapter 4, we will
show how different surfaces can be split on the original topology file. For now, we use the
entire surface to remodel the part. A scanned model will also result in a single triangulated
surface that needs further segmentation.

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1.2. Surface manipulations of raw topology data

Filling the screw holes

Rough screw holes

Due to the rough meshing, the quality of the screw holes
is completely lost on the raw data. The easiest way to
regain the good quality, is to:

 Fill up the holes

 Smoothen the rough model
 Create clean holes using the Design Space

1. Change view to Triangle View

o View bar on left side of screen

o Sphere >

2. Fixing toolbar: Reduce

o Reduce will lower the amount of triangles, taking into account a certain geometrical error
= deviation (mm) from the original
o Entities: select the part (KMWE_STL_raw_data) on which the triangle reduction needs to
be performed
o Reason: Larger triangles enable an easier marking of the surfaces

The parameters indicated in yellow are visible if the expert mode is turned on. This mode can be activated
By clicking on “Expert Mode” in the bottom of the 3-matic window.

3. Mark toolbar: Wave brush mark

o Change in Operations pages the diameter to 0.5 mm
o Mark each area in a hole with the mark brush
 Tip: use CTRL + marking brush to unmark triangles

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4. Press Delete to remove the marked triangles.

o The meshed model now contains holes, so it is not possible to produce the part in this state.
o In the Object Tree, you can see that a list of “bad contours” is identified.

The yellow lines indicate where the mesh is not closed. Due to these open Overview of all the bad contours in the
surfaces, you can look inside of the part (red surfaces). Object Tree

5. For automatic STL fixing; press on Fixing toolbar > Fix Wizard
o First, the Fix Wizard provides an overview of all the errors present in the STL file.
o Select the part that you want to be analyzed.
 Selecting the part can be done by clicking on the part name in the Object
Tree or immediately on the model itself in the work area.
o Press on “Update” to see the different kinds of errors.
 Note that overlapping and intersecting triangles can be ignored most of the
times
o By pressing on “Follow Advice” the part will be fixed automatically
 This is a step-based approach, so it may take some clicks to get the part
fixed.

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The Fix Wizard is often capable to automatically fix the entire part in a few clicks. So the Fix
Wizard can also help to fix the errors of other error prone models and thus make the part
printable.

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Wrapping
The current mesh of the raw topology data is very rough. A first step that can be used to
remodel the part, is to wrap a new STL surface around the existing one. In later steps, the
wrapped surface can be further smoothened and cleaned, so a clean model can be exported.

6. Design Toolbar > Wrap

This operation will wrap a new STL surface around the selected part using the following parameters:
o Smallest detail will determine the size of triangles used during the creation of the new
surface. Smaller triangles will result in longer calculations, but still closely represent the
original model.
o A small resulting offset is useful, to be sure no material is removed from the optimized mesh.

Wrap without an additional offset Wrap with an additional offset of 0.5 mm

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Overall result after wrapping operation with 0.5 mm offset.

Note that a new part is created in the Object Tree.

Smoothing
Next, the overall surface can be smoothened to gain a more organic result. The smoothing
algorithm gets rid of all sharp zones on the surface of the part.

Basic principle of smoothing

7. Go to Fixing Toolbar > Smooth

o Entities: complete part or only one surface are possible
o Use compensation: This checkbox will apply an additional offset after the smoothing, so
less thickness is lost in the model. Yet, the smoothing effect can be a bit weakened.

Example of parameters that can be used during After multiple smoothing operations
smoothing (after pressing “Apply” multiple times)

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More mesh manipulation tools

To further refine the mesh, use a combination of

Fixing > Reduce : Reducing the triangles with a certain geometrical error
(=deviation from original mesh) straightens locally the
mesh

Fixing > Subdivide : A more detailed mesh will give more accurate
smoothing and less shrinking of the model.

Fixing > Smoothing : With or without compensation.

NOTE: The overall goal of this process was to make sure that the organic part of the model
is sufficiently smooth, so it represents a clean model to print and the surface is clean enough
to be exported as NURBS.
The smoother the mesh, the lower the tolerances can be put to export towards CAD
surfaces.

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1.3. Redesign CAD-like entities

The organic surface we created is typically too organic for the mechanical purposes. The
cylindrical screw holes and the bottom plane still need to be reconstructed. The easiest tool
to perform this operation is to make an intersection between the Design Space and the
topology optimized mesh.

8. Go to Design Toolbar > Boolean intersection

o Entities: Design Space and the wrapped and smoothened mesh.

The Design Space and cleaned topology optimized mesh Result after Boolean intersection

The resulting part is a clean STL file that fits in the given Design Space and contains the
same surface splits on the boundary surfaces. Next, the organic surface is sufficiently
smooth to patch it with NURBS that stick close to the original topology optimized result.

For the more experienced user, more analytical surfaces can be made for an even better
result. These advanced design operations are not considered as the goal of this tutorial.

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1.4. Towards FEA

To properly calculate the strength of the optimized part, you need to export a clean mesh
towards simulation packages. Using the 3-matic Remesh module, you can perform all the
prerequisites to properly analyze the part in FEA:
 Generation of a uniform triangle mesh
 Generation of uniform volume elements
 Export towards simulation packages

Generation of a uniform triangle mesh

9. Go to Remesh Toolbar > Adaptive Remesh

o Find below an overview of the parameters used during the surface remesh

 Entities: This indicates the part or surfaces to

be remeshed.
 Shape Measure: This is the strategy to
describe how equal the sides of each triangle
should be. R-in/R-out is the difference ration
on the inner and outer circle in a certain
triangle.
 Shape quality threshold: The higher the value
of uniformity, the more equal the sides of a
triangle are, but the longer the calculation
takes.
 Geometrical error: This indicates how many
millimeters the new mesh is allowed to differ
from the original.
 Control max edge length: Triangle size will be
limited on (for instance) flat surfaces
 Preserve surface contours: The contours of
each surface are maintained.
 Local remesh parameters: If particular
surfaces need to be remeshed more
accurately, you can specify local remesh
parameters in this section.

Example:

Before Remesh
After Remesh

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Generation of uniform volume elements

Once a uniform surface mesh is generated, you can generate solid elements within the STL
volume. To do so:

10. Go to Remesh Toolbar > Create Volume mesh

o Note that in order to generate solid elements within the part, you need to be sure that the
STL does not contain any bad contours, nor intersecting triangles.

To analyze and fix these potential errors, you can use the Fix Wizard (Supra)

A clean mesh that is fixed by the Fix Wizard,

found in the fixing toolbar Section view of cleaned result with solid elements.

Export to FEA packages

To export the mesh towards different FEA packages, you can
 go to: File Menu > Export > Abaqus / Ansys / Nastran / Patran / Fluent / Comsol
 Parameters can be chosen to export the volume and surface mesh. It will keep the predefined
surface splits during the export.

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1.5. Towards CAD

If the part has been remodeled in a proper way, you can also export it as an .iges or .step
file, using the CAD Link Module. In order to perform this step, you need to be sure the
following requirements are met:

 Surfaces must be as smooth as possible

o Small triangles with a very smooth alignment.
o As described above, there is a large amount of features to play around with the mesh.
o The more accurate the mesh, the lower the tolerances while exporting towards CAD.

 Intersecting and overlapping triangles must be removed.

o These can be fixed automatically with the Fix Wizard.
o The presence of intersecting and overlapping triangles can make the export to CAD
surfaces impossible on those zones.

 Small sharp artefacts of the mesh might result in a hotspot of surfaces.

o Make sure you remove them properly.

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Once you feel confident that the issues mentioned above are not present, follow the
instructions below.

 Go to CAD Link toolbar > CAD Link

o Some interesting parameters can be used to export the part as CAD surfaces

 Entity: This indicates the part to be exported.

 File type: Select the file format to be exported.
 Reverse to NURBS only: No entity recognition is
used on the surfaces, every surface will be
patched with NURBS. Better put this off.
 Automatic splitting: Complex surfaces will be split
automatically in order to export properly. Better
put this checkbox on.
 Patch density: Intuitive value on the complexity
of the part. Very complex and highly curves
surfaces require a bigger patch density.
 Preview: This gives a first indication on how the
part will be exported with a given set of
tolerances. It is useful to find local irregularities
in the surface of the part.
 Tolerance: For the best behavior, it is highly
recommended to click on “Estimate” before
performing the operation. This will propose a
reasonable tolerance to export the part, based
on the mesh quality. The default values can be
too detailed and thus result in excess CAD
surfaces.

NURBS representation of the post-processed bracket

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2 Exercise 2: Design changes and labeling

2.1. Introduction to forward engineering
The unique forward engineering concept of 3-matic is driven by
the numerous CAD & sketcher operations. The possibility of
applying these standard ‘CAD’ function directly on mesh data
opens different application areas and shortens design cycles
tremendously. Examples of possible design applications are:
 add rounds or reinforcement structures
 create life-like prototypes by automatically applying a pattern
(e.g. logo’s or perforations) on the design
 split up parts in easy-to-build components for easy finishing
and assembling afterwards
 easily add text, labels or even bitmaps (e.g. of logo’s) to a
sketch. These are very useful, intuitive tools for design
modifications or part identification.
 apply morphing operations on freeform data for smooth and
slight design changes

2.2. Required material

Package & optional modules:
- 3-matic Fixing
Files:
[Link]

2.3. Design changes

In the first part of this exercise a method will be explained to create a new part with the same
geometry but with a better quality mesh and a thickness for this bottle. 3-matic offers different
methods to create a thickness at this part; this can be done by a sketch, or a hollow
operation.

Import [Link]
1. Open 3-matic and select “File” , select “Import”, select “STL”, select the “[Link]”
2. Don’t check the “split surfaces” option in the import options window.

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3. The part will be loaded in the 3D view.

Create inertia axes

The part is not nicely positioned according to world coordinate center. 3-matic offers the
possibility of calculating point of gravity but also to calculate the inertia axes of a part. By
calculating inertia axes, these can later on be used to position symmetry planes and indicate
revolve axes.

1. Open the ‘Analyze’ toolbar, select the ‘Create Line’ operation

2. Select the ‘Fit Inertia axes’ in the Method box. Select the Bottle for the ‘Fitting Entities’ and apply
the operation. As a result 3 inertia axes are created and visualized.

NOTE: instead of creating inertia axes, it is also possible to reposition an object’s coordinate system to
a different coordinate system (e.g. based on inertia axes). This can be done via the ‘Update OCS to
CS’ operation in the edit menu/toolbar.

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Create and position a sketch

The created inertia axes can be used to create a sketch plane positioned as a symmetry
plane. The sketch should therefore be created such that the axes of the sketch will match
with the inertia axes.

1. Open the ‘Sketch’ toolbar; select the ‘New Sketch’ operation .

2. Select the three points of the sketch as shown in the figure below. Select ‘Apply’.

Point 1

Point 3

Point 2

3. A new sketch is now be created in the 3D view and in the active scene.

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Import geometry in the sketch

The intersection lines between the part and the sketch can be created in the sketch, for
design purposes.

1. Select the ‘Import References’ operation in the ‘sketch’ Toolbar.

2. Select the Bottle in the “intersection selection’ box.

3. If all needed selections are filled in select ‘Apply’.

4. Open the sketch tab, next to the Work Area.

5. The intersection line (=’context curve’) of the bottle is now visible in the sketch.

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Give the geometry a thickness

Creating a thickness and other design changes can be executed in the sketch. The resulting
sketch will be used for a revolve operation afterwards, to recreate the bottle.

1. Make sure the imported context curves have the “construction property” OFF. Select the “context
Curve” in the Active scene. Uncheck the “construction” box in the properties page. This because
‘construction’ lines are only visible in a sketch, but will be ignored for creating a 3D afterwards.

2. Select the ‘Offset’ operation in the Sketch toolbar. Select the Context Curve in the Entities
box. Give the bottle a thickness of 2mm. Make it an internal offset. Uncheck the ‘Remove
original’ checkbox. Make it ‘Round’ convex corners.

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Trim the sketch-lines

A revolve operation will rotate the sketch over an angle of 360°. Therefore half of the sketch
needs to be trimmed away.

1. Before creating the line, click on the ‘Toggle construction by default . After doing this all the
sketch design that is done, will receive the property ‘construction’, and thus not used for 3D
operation (such as the revolve operation)

2. Select the ‘Create Line’ operation in the Sketcher toolbar. Create a line as shown in the
figure.

3. Select the Trim operation in the Sketcher Toolbar. Trim the two curves in the sketch as
shown in the figure.

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Create an edge at the bottle

This step will show how to make a small design change at the bottle.

1. Before doing these design changes in the sketch, disable the ‘Toggle construction by default .

2. Select the ‘Create Circle’ operation in the sketcher Toolbar. Create a circle which snaps to the
outer surface of the bottle.

3. To create Constraints for the circle, start with selecting the circle in the database tree. All possible

constraints will be highlighted now. Select the “Set Radius” constraint .

4. Fill in a radius of 3.0mm and apply the operation.

5. Select again the Trim operation in the Sketch Toolbar. Trim the lines in the sketch as shown
in the figure.

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Open the bottle at the top

To make it an open bottle, the top lines of the bottle need to be cut off. Therefore an extra
line will be created.

1. Select the ‘Create Line’ operation in the Sketcher toolbar. Create a line which is horizontal.

2. Select the ‘Trim’ operation in the Sketcher toolbar. Trim the lines to obtain a result as shown
in the picture.

Convert the 2D sketch design to a 3D part

1. Go back to the Work Area. Select the original bottle, Press RMB, select ‘Hide’.

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2. Select the ‘Revolve’ operation in the Design toolbar. Select the sketch in the entities box.
Select the x-direction from the sketch as revolve direction via the 3D view or in the active scene.
Change the name in the ‘New part name’ box into ‘Revolved Bottle’. Apply the operation.

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2.4. Labeling
In the second part of this exercise, a label will be created on the surface of the bottle. This
label can be created by yourself in 3-matic or you can import the label (*.bmp). Here we will
create a text label in a sketch in 3-matic. This label will be folded around the cylindrical
surface of the bottle.

Create new sketch

1. Select the ‘XY-plane’ of the ‘world coordinate system’ in the active scene. Click RMB, select new,
sketch.

Create label in sketch

1. Go the sketch view; select the ‘sketch-002’ tab.

2. Select the ‘Create Label’ operation in the sketcher toolbar. Create a label as shown in the
figure.

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Sketch folding
1. Go back to the Work Area
2. Select the ‘Sketch Folding’ operation
(under the ‘export’ operation) in the sketcher toolbar/menu.
Select the ‘Revolved Bottle’ in the ‘Part’ box. Select the sketch
with the label in the ‘sketch’ box. The ruled surface direction is
the direction which will match with the y-direction of the sketch.
As the label must be folded around the x-direction of the first
sketch, we select the x-direction in the active scene of the
sketch.
3. Select a point on the surface of the bottle which must match
with the origin of the sketch. The red arrow will match with
Y-direction of the sketch and the purple arrow will match
with the X-direction of the part. Make sure that these are
placed in a correct way as shown in the figure.
4. Check the boxes ‘attract curve’ and ‘Split Surfaces’. The
separated surfaces (the label) can than later be embossed.
Select ‘Apply’

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5. The label is folded over the cylindrical surface.

Emboss the label

To emboss the label, the separated surfaces from the label will be moved in their respective
normal directions.

1. Select the ‘Move Surface’ operation in the Design toolbar. Select the first surface of the label
(the ‘3’). Move the surface over a distance of 1.2mm. Select ‘Apply’.

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2. Repeat the previous step for each letter of the label, with the same parameters.

3. Select the curves in the curve list and delete them.

Final result of redesigning and labeling the bottle part

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3 Exercise 3: Point cloud to STL

3.1. Introduction to point cloud module
The point cloud module makes it possible to modify
point clouds in 3-matic and to convert them to STL
files. The module includes the import & export of
different point cloud formats. Furthermore a range
of tools is available to modify point clouds by
marking, sub sampling, noise reduction, splitting…
to improve the quality of the point cloud.

Special tools are available for registration of multiple point clouds or STLs and to glue
different (overlapping) meshes, originating from different point clouds, into one solid mesh.

3.2. Required material

Package & optional modules:
- Materialise 3-matic Fixing + Point Cloud module
Files:
Cushion_Panel.asc

3.3. Point cloud meshing

Import point cloud
1. Select Import > Point Cloud from the ‘file menu’. Select the Cushion_Panel.asc file.
2. An import dialog box appears. The default settings are fine and can be kept. Click on OK to import
the point cloud
3. The point cloud is imported in 3-matic and visualized in the 3D view. The properties of the point
cloud reveal that it consists out of 50474 points.

The imported point cloud

Preparation and meshing

1. In order to reduce the amount of points but also to optimize the point distribution, open the ‘sub

sample’ operation from the point cloud menu/toolbar.

2. Select the Cushion_Panel point cloud and reduced the amount of points to 75%.
3. Verify in the property page that the amount of points is now 36708 points.

4. Open the ‘Mesh Data’ operation from the same toolbar/menu.

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5. This operation will create an STL mesh from any selected point cloud. Apply it with the default
settings. As a result a part called ‘Cushion_Panel’ will be created.
6. Hide the point cloud via selecting it and selecting ‘hide’ in the context menu of the point cloud.

Result of meshing

3.4. Scan fixing

Typically, borders in a scanned object will never be smooth and accurate. To reconstruct
these features, 3-matic offers different fixing possibilities. In this case the circular holes will
be refined with the use of the slot restoration tool

Before slot restoration

1. Open the ‘slot restoration’ operation of the fixing toolbar/menu.

2. Select one of the circular bad contours for the operation

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3. By default, the operation will fit a perfect circle. If desired, the parameters for this outline can still
be changed. For now, leave them to default. More important are the ‘Hole fill parameters’. Because
the triangles at a border of the scan are typically already noisy and less accurate, the slot restoration
operation offers the possibility to remove these border triangles (expand hole). Change the ‘Hole
fill parameters’ therefore to:

4. Apply the operation

5. Repeat this for the other holes as well.

Result of slot restoration

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4 Exercise 4: Reverse engineering

4.1. Introduction to CAD link module
Split freeform geometry automatically and save time
The CAD link module offers swift and accurate conversion of freeform geometry to CAD.
For complex geometry, where segmentation is a necessity, manually splitting geometry in
definable patches can be a time-consuming job. Using 3-matic’s CAD link module, a splitting
algorithm for freeform geometry automatically splits the entire geometry in definable patches
of similar size. The number of automatically generated patches is limited, making sure you will
not end up with an excess of small patches. Conversion is possible to both the IGES as STEP
format.

Recognize CAD-like entities and keep features after conversion

The advantages of the CAD link module become even more apparent when combining the
manual and automated methods for segmentation. On an initial segmentation, feature
recognition is performed first, ensuring that CAD-like entities will be exported as CAD entities,
such as planes, cylinders, etc. Recognizing the CAD-like entities this way guarantees that
features are kept after conversion and reduces file size. This feature recognition allows you to
start working with a specific CAD entity immediately after conversion to CAD. On the other
hand, a larger NURBS surface in the region of interest can also be obtained by making a
separate segmentation of this area first.

4.2. Required material

Package & optional modules:
- Materialise 3-matic Fixing + CAD Link module
Files:
- Lion_Cavity.mxp

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4.3. Preparation of the STL

The CAD link operation of 3-matic provides reverse

engineering based on the surface structure. Every
surface will be considered separately to convert into
a CAD-face according to the following principle:

 First feature recognition is done. If a surface can

be recognized as an analytical primitive such as
plane, cylinder, revolve surface, NURBS … then
this surface will be reversed to a primitive face.
 If feature recognition fails, e.g. on freeform
(scanned) surfaces, an automatic patching will
start. This will split up the surface in different
patches, which then can be converted into NURBS
faces.

This principle requires an initial surface segmentation of STL files before conversion. Using 3-
matic, this surface structure is automatically generated and preserved in all operations.
Boolean operations, CAD operations … all will preserve and/or generate a surface structure.
On the other hand, surface segmentation can be done as well using automatic and manual
operations such as marking and curve operations.

1. Open the ‘lion_cavity.mxp’ project, by choosing ‘open project’ from the ‘file menu’. This project
contains one part, called ‘Lion Cavity’. The part already contains a surface structure, which is
preserved in the project file. No further preparations is needed on the file.

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4.4. Reverse engineering

1. Open the ‘CAD link’ operation from the CAD link toolbar/menu. Select the Lion Cavity part for the
operation. Reverse engineering means that 3-matic will convert a file from STL to STEP or IGES.
2. Just like importing a CAD file and converting it to STL, the reverse engineering also requires
tolerance parameters to be set. As these parameters depend from part to part (depending on
curvature, size …) you can estimate these settings by clicking the ‘estimate’ button at the bottom
of the operation page.
3. Before applying the operation, the other parameters need to be set as well. Important parameter is
the ‘patch density’. It determines in how many patches 3-matic will minimally split the surfaces that
were not recognized as a primitive feature. For this example 20 is a more optimal number.
4. Create a preview of the patching by clicking on the ‘preview’ button. Creating a preview is in fact
already a first step of the reverse engineering process, namely the feature recognition and automatic
patching is already done.
5. Upon applying the operation, the actual conversion to IGES or STEP is done, and the file is written
to the specified location.

Left: the preview of the reverse engineering

Right: the CAD link operation page and parameter settings

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4.5. Result
The result of the CAD link operation is a STEP or IGES file in the specified location. But also
the logger window is giving feedback on the reverse engineering. Here you can clearly see
that 6 planes and 4 cylinders have been recognized in the part, based on the surface
information. The ‘freeform’ surface has been converted into 244 NURBS patches.

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5 Exercise 5: Conformal cooling channel design

5.1. Introduction to tooling module
Tooling design
In the tooling module, parting lines can be defined
automatically and different kinds of algorithms for
parting planes are available. This enables you to
position the parting line where you need it. Once the
design in the tooling module is finished, you can
proceed with the design in 3-matic design. The
combination of design tools (sketching, CAD
operations, curves…) with special tooling operations
offer the solution for creating complex inserts,
slides, 3D cooling channels, runners… with ease.

2D drawing
The tooling module includes as well the possibility to create a technical 2D drawing of your
tool designs.

5.2. Required material

Package & optional modules:
- Materialise 3-matic Fixing
Files:
- Lion_Cavity.mxp

5.3. Creation of centerlines for conformal cooling channels

Creation of hollow part
1. Open the project ‘Lion_Cavity.mxp’ via ‘Open project’ in the File menu.

2. Using the ‘hollow’ operation of the Design toolbar, it is possible to create a new surface at a
certain distance from an input part. This surface can then be used as the base surface, to freely
draw curves on, later on being the centerlines for the cooling channels.
3. Select the Lion Cavity part for the operation, and set the parameters as following:

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4. As a result, a new surface is created at a distance of 7mm inside the part. Move this new surface to
a new part, by selecting it in the database tree, click on RMB and select Separate > Move to new
part in the context menu.

5. Hide to original part (Lion Cavity) and rename the newly created part to ‘Hollow result’.

6. As a result you will now see the hollow part in the 3D view. Any curve drawn on this part, will be at
7mm distance from the original cavity. These curves can then be the centerlines of the cooling
channels. Creating a cooling channel with a radius of 2mm will then result in having a perfect
distance of 5mm between cooling channel and parting surface.

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NOTE: you can verify the result as well by showing the Lion Cavity again, and showing as
well the ‘Standard Section – X’ in the database tree.

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Creation of curves
1. Create a new sketch by selecting the ZX-plane in the database tree, click RMB and select New >
Sketch

2. Import the projection of the surface contour of the lion surface (of the original cavity) and import the

outline of the hollow result into the sketch, via the ‘Import References’ operation of the sketch
toolbar.

3. Go to the sketch scene, via clicking on the sketch tab.

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4. In the sketch, create a line sequence, using the ‘Line Sequence’ operation, which can be found as
a dropdown next to the Line operation in the sketch toolbar. The imported context curves will help
you in positioning the lines. Make sure the lines are wider than the lion.

5. Go back to the Work Area. The line sequence

that has been created can now be projected on
the Hollow part. To do this, open the ‘Project

curve’ operation in the curve toolbar/menu

6. Select the sketch for the ‘entities’ box, and the

Hollow result as a target entity. The other
default settings are fine, except for the
projection direction. Indicate the negative Y-
direction for the projection direction.

7. Apply the operation and then hide the sketch.

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8. As a result, the sketch curves have been projected on the hollow part and a curve entity is added in
the database tree of the Hollow result. It is now still necessary to enlarge the curves at the end
points, so that the curve is coming out of the original Lion Cavity. That will ensure that a Boolean
subtraction operation can be done afterwards.
9. First, hide the surface of the hollow result, via selecting ‘Surface List’ and choosing ‘Hide’ in the
context menu (RMB click)

10. To enlarge the curves, open the ‘Enlarge curve’ operation from the curves toolbar/menu. The
length of the free curve that will be added, should be 30mm, to be certain it is larger than the original
Lion Cavity. Apply the operation.

11. From the (hidden) Lion Cavity, select the lion surface in the database tree and copy it to a new part,
via the context menu. The new part will have the name Lion Cavity-001, indicating that it is
originating from the Lion Cavity part. It is now visible that the curves are nicely following the shape
of the cavity, at a fixed distance of 7mm.

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Distance to curve check

It is possible, using analyses, to verify the correctness of the created centerlines. A distance-
to-curve analysis can reveal the actual distance between a curve and a part.

1. As the analysis will be visualized on the front face of triangles, first the orientation of the triangles of
the part Lion Cavity-001 needs to be flipped. This can be done by selecting the part, and clicking

on the ‘Invert Normal’ operation in the fixing toolbar/menu.

2. Then open the ‘Create Distance-to-Curve Analysis’ operation from the Analyze toolbar/menu.
After making the selection of Lion Cavity-001 and the corresponding curve, apply the operation

3. As a result, the distance between Lion Cavity-001 and the curve is calculated and represented via
a histogram (properties of the created analysis) and accordingly visualized via coloring the part. In
the histogram some statistical information is available as well, informing that the minimum distance
between curve and part is indeed 7mm (due to the ‘discrete’ nature of an STL, this value will never
be perfect 7mm).

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5.4. Creation of conformal cooling channels in cavity

1. Open the ‘Create Cooling Channel’ operation in the Tooling toolbar/menu. Select the centerline
curve and indicate a channel diameter of 4mm, before applying the operation.
2. As a result, the part ‘Cooling Channel-001’ is created.

3. Show the original Lion Cavity again and hide the Lion Cavity-001 part.
4. The created cooling channels will stick out of the Lion Cavity part, so that a Boolean subtraction

can be performed. The ‘Boolean Subtraction’ operation can be opened via the Design
toolbar/menu. Indicate the Lion Cavity and Cooling Channel-001 part respectively as Entity and
Subtraction Entity. The other parameters can set as indicated in the screenshot below, and then the
operation can be applied. As a result, the Lion Cavity now has conformal cooling channels added
to its geometry.

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6 Exercise 6: Create a texture

6.1. Introduction to the Texturing module
The texturing module offers the possibility to apply 2D/ 3D textures on a surface. This will be
done based on a picture (*.Jpeg, *.Bmp or *.png).
The first step of applying a texture is wrapping the bitmap on a surface. The second step will
give an offset to every pixel of the picture. This offset-value is depending on the black/ grey/
white color in the picture.

The first picture above shows a part with the picture applied on the surface. The second
picture shows the 3D picture created, based on the picture.

6.2. Required material

Package & optional modules:
- Materialise 3-matic Fixing + Texturing module
Files:
- [Link]
- Picture with pattern (in this case: [Link])

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6.3. Create a surface for texturing

Import [Link]
1. Open 3-matic and select the File menu, select ‘Import Part’, select the [Link]
2. Make sure the option ‘split surfaces’, with the split method 30 degrees, is checked OFF, Select ‘OK’.

The part is imported in 3-matic and visualized in the Work Area.

Create a surface
The texture will be created on the front of the shoehorn. First a surface will be created on the
front of shoehorn.

1. Select the Mark Toolbar > select the ‘Mark Smooth Region’ operation > Mark the front of the
shoehorn > Right-click on the marked triangles > Separate > Move to Surface > Create New.

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To create a small edge without texture, an offset will be given to the contour line.

2. Select the Texturing toolbar > select the ‘Create Iso-curves’ operation > select the outer contour
line of the surface > select an interval distance of 3mm.

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To split and close the existing curve:

3. Select the texturing Toolbar > select the ‘Split curve’ operation

4. Press Esc > Select and delete the smaller separated part of the curve

5. Select the ‘Close Curve’ operation > select the ‘Free curve’ option.

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Since this curve is connected with the surface, this will be first attracted on the surface,
during this operation this surface will also be split.

6. Select the Texturing toolbar > select the ‘Attract Curve’ operation > select the curve and the
surface.

The surface is created:

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6.4. Create a 3D texture

Apply the 2D texture
The first step of creating a texture is selecting a bitmap which will be wrapped on the surface.

7. Select the Texturing Toolbar > select the ‘2D texture’ operation. > select the surface to apply
the texture. > select a bitmap, named ‘Tiles’. > select ‘Apply’.

To change the properties of the bitmap, select the 2D texture. You can select the 2D texture
by clicking on the 2D texture in the 3D view, or by opening the tree of the part in the
database. Select the Properties Tab.

By changing the ‘Width’, you can rescale the part.

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Convert to a 3D texture
Now the 2D texture is created, this can be converted to a 3D texture.

8. Select the Texturing toolbar > select the ‘2D to 3D Texture’ operation > select the parameters
below.

For all the black pixels we choose an offset of -0.2mm, for all the white pixels we choose an
offset of 0.4 mm. Before selecting the ‘Apply’ button, estimate the Memory. This gives an
idea if the operation will succeed or not with knowing the capabilities of your system.

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7 Exercise 7: Design a 3D pattern

7.1. Introduction to the Patterning module
The Patterning module offers the possibility to apply 3D pattern on a surface. This will be
done based on a pattern entity (CAD, STL).
During the first step a 2D pattern will be created, this will give the possibility to set the
dimensions, position and direction of the pattern. During the second step a pattern element
will be selected and this will be copied over the whole surface.

Step 1: 2D pattern Step 2: 2D to 3D pattern

7.2. Required material

Package & optional modules
- 3-matic Fixing + Texturing module
Files
- [Link]
- Ring_2.mxp

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7.3. Create a 2D Linear Pattern

Import the part
1. Select the File menu > select ‘Open project’ > select ‘[Link]‘

Import the Pattern entity

2. Select the File menu > select ‘Import part’ > 3DPatternUnitLibrary > Select ‘ring_2.mxp‘

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Create a 2D linear pattern

1. Select the Texturing toolbar > select the ‘2D linear pattern’ operation > select the outer surface
of the cover in the ‘Entity’ box. > select Apply.

The UV page allows it to make changes in the dimensions of the 2D pattern and position and
rotation. The dimension of the 3D pattern will be controlled by the dimension of the pattern
element ‘ring_2’. Cancel the 2D pattern operation or press the escape button on the
keyboard to close to UV page.
If needed, the orientation of the 2D linear pattern can be adapted such that it is linear with
the edges of the part or give it the desired orientation. In Object Tree > Cover > Pattern List >
2D Linear Pattern, use the following dimension properties to make this design fit properly:

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7.4. Create a 3D pattern

2D to 3D Linear Pattern
To create a 3D pattern, a pattern will be created with the ring_2 pattern entity over the
surface. This will be done with the 2D to 3D pattern operation.

2. Select the Texturing toolbar > select the 2D to 3D Linear Pattern operation. > select the
following parameters and select the preview button.

A preview will be shown in the UV view and in the work view. Now it is still possible to
change the dimensions parameters and the position of the 2D pattern.

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Preferred distance: -1.000: this creates a small overlap between the single pattern elements
as shown in the figure below.

Depth: 2mm: the thickness of the cover is also 2mm. The solid cover will be replaced with the
new 3D pattern result. The height of the pattern entity is also 5.5, so this will create a full
intersection of the pattern entity in the cover.

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Result of the preview:

If the result is not satisfying, the dimensions of the 2D pattern and the position can still be
changed by checking the “edit 2D pattern” ON, the dimension parameters will appear in the
operation page. If the result is ok you can skip this step and select the desired result, which
is a “No merge” in this case. We keep the two results separated, because the solid surface of
the cover will be removed and replaced by the rings in the end.

3. When the preview is satisfying, Select ‘Apply’. The final result is shown in the next figure.

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This result is not 3D print ready. The inside of the cover has to be removed.

Remove the inside of the cover

4. To remove the inside of the cover additional edges will be created. Right click ‘3D pattern result’ >
Hide. Right click ‘Ring-O2’ > Hide.

5. Select the texturing toolbar > select the ‘Create Isocurves’ operation > select following
parameters, and select the contour line of the cover surface > Apply.

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We only need the top offset, therefore the bottom offset is selected and deleted as shown in
the figure below.
6. Select the curve > RMB > Delete

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The hole on the outside of the cover will be preserved as well:

7. Select the contour line > Right-click > new > Curve:

These curves will be attracted on the inside of the cover.

8. Select the texturing toolbar > select the ‘Attract curve’ operation. > select the two previously
created curves in the entity box and select the following parameters > select the inside surface of
the cover as target entity > apply.

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Result:

Next, the top surface needs to be split.

9. Select the texturing toolbar select ‘Split surfaces by curves’ > select the outside face of the
cover as entity, as shown below > use the following parameters > For the split curves displayed, the
previously created curves should be selected > Apply

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Now the surfaces on the inside and outside can be removed.

10. Select the inside and outside surface (hold down the ‘Ctrl’ key while selecting) > delete.

Result:

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Close the open edges:

11. Select the Fix toolbar > select the ‘Fill hole normal’ operation > select the two open bad
contours > Select ‘treat as one hole’ option > Apply

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Result:

If this result is not shown correctly, try to invert the normal. Select the newly created surface
from the Object Tree. Select the Fix toolbar > select the ‘Invert Normal’ operation . If the
result is correct, continue with the next steps.

12. Repeat the same step for the remaining two bad contours:

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An offset will be created on the edge of the cover. To get a good view at the overlap of the
pattern and the cover:
13. Select ‘3D pattern Result’ from the Object Tree > RMB >Show.

To create the offset:

14. Select the design toolbar > select the ‘Move surface’ operation > select the surfaces as shown
in the figure below> select the following parameters > Apply

To get a good look at the overlap of the pattern:

15. Select ‘cover’ > ‘pattern List’ > 2D Pattern, RMB > Hide.
Result:

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For the inside edge an offset operation will be used:

16. Select the design toolbar > select the ‘Uniform Offset’ operation > select the following surface:

Result:

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Remove small parts

Now the last step is removing some shells which are sticking out and merging all the parts.
First we start removing all the shells which are too small and will not create a strong
connection with the rest of the cover; example below:

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17. Select the Fix toolbar > Select the ‘Filter Small Shells’ option > Select the ‘3D pattern Result’
from the Object Tree and choose the parameters as depicted below:

18. In the Object Tree, select the ‘marked triangles’ in ‘3D pattern Result’ > RMB > delete.

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You can also give a thickness to the inside hole of the cover, but first we need to unite these
two faces:

19. Select the Mark toolbar > Mark Smooth Region > select the top region as shown below >
RMB>Separate > Move to Surface > Create New

20. Select the Design toolbar > select the move surface operation > Select the united face and the
parameters as shown below:

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Result:

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7.5. Merge all parts

The last step is to merge all the parts in to one part.
21. Select the Design toolbar > select the Boolean union > select the two parts and following
parameters:

Final result:

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8 Exercise 8: Design a perforation

8.1. Required material
Package & optional modules
- 3-matic Fixing + Texturing module
Files
- [Link]

8.2. Create a 2D Linear Pattern

Import the part
1. Select the File menu > select ‘Open project’ > select the [Link]
The project contains the cover. To make a perforation, an entity for the pattern is needed.
This pattern will be perforated in the cover.

Make an entity

2. Select the Design Toolbar >> select Create Cylinder

Use the following properties:

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Create a 2D linear pattern

3. Select the Texturing toolbar > select the 2D Linear pattern operation > select the top surface
of the part in the ‘Entity’ box. > select Apply.

The pattern can be adapted by selecting 2D Pattern in the Object tree.

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8.3. Make a perforation

To perforate the part, a pattern will be created with the cylinder over the surface. This will be
done with the 2D to 3D pattern operation.

4. Select the Texturing toolbar > select the 2D to 3D Linear Pattern Operation. > select the
following parameters > select the Preview button.

Make sure the Subtract results is selected in desired result, as this will make a perforation. A
preview will be shown in the UV view and in the work view. Now it is still possible to change
the dimensions parameters and the position of the 2D pattern.

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If the result is not satisfying, the dimensions of the 2D pattern and the position can still be
changed by checking the “edit 2D pattern” ON, the dimension parameters will appear in the
operation page.

5. If the result is ok > Select Apply

Result:

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9 Exercise 9: How to make a randomized structure

9.1. Required Material:
Package & optional modules
 Materialise 3-matic Design + Lightweight structures module
Files:
[Link]
o C:\Program Files\Materialise\Materialise 3-matic 11.0 (x64)\DemoFiles

9.2. Create Unit Graph

Import 3-matic project (*;mxp)
1. Select the File menu > select ‘Open project’ > select the [Link]

Interface:
The 3-matic project contains 3 different parts:
 Solid Volume: the volume that will be printed as solid material, basically the inside of the cup.
 Lattice Volume: a volume has been indicated in advance on where the lattice needs to be
applied to.
 Dodecahedron: this is the unit cell that is going to be used to generate the controlled
randomization of the porous structure.

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To generate a lattice structure, 3-matic uses a new

type of entity, called a graph. Graphs are a bunch
of line elements that represent the lattice structure
in a simple way. This enables a fast and quick
way on generating and modifying different kind of
lattices.

The default color of the lattices is red, because it

indicates (as a warning color) that no thickness
has been assigned yet to the lattice. The rendering
can however give a thickness preview. This is
done in the button “toggle graph rendering” in the
left view toolbar

Uniform Unit Graph

Unit graph is an operation that is commonly used to duplicate a graph set (=Dodecahedron)
into a certain volume (= Lattice volume). The default parameters of the Unit Graph function
will perform an XYZ duplication of the same unit cell.

2. Select the Lightweights toolbar > Create Unit Graph > Use the following parameters for a
uniform unit graph> Apply

Entities: The volume that needs to be filled up with the

lattice
Graph Set: The bundled graph lines that make up one
unit element.
Graph Structure Size: changes the size of the unit in
the end result.
Keep Aspect Ratio: Keep the same XYZ ratio of the
existing graph set. Changing one dimension, will
automatically change the dimension of the others.
Keep Surface: The STL surface is maintained after
the unit graph operation. The nodes of the mesh will
correspond to the outside nodes of the lattice.
Create shell: An extra shell will be created to design a
solid skin around the part.
Shell thickness: Specify the thickness of the solid skin/
shell.
Direction: the extra shell of the solid skin will be inside
or outside the original shell created.
Detail size: specify the size of the new created
triangles.
Merge all graphs: the created graphs will be merged
into one graph set.
Randomize Graphs: the graphs will be randomized.

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The end result after this operation will thus result in a very simple duplicate unit cell in the
given volume. Off course, because we still didn’t assign a thickness to the lattice, we still
have a lattice that is visualized in red. How to assign a thickness will be explained later in the
tutorial.

Instead of a Uniform unit graph, it is also possible to choose a randomized unit graph.

Randomized Unit Graph

The randomization will work by an up and down scaling of a given unit cell. Means a unit cell
with a size of 1x1x1mm will be scaled up and down with a given percentage. These variation
around the reference unit cell is a normal distribution, so the pore size will be
distributed/scaled up and down accordingly.

No randomization gives a simple

duplication in the XYZ dimensions of
the same (cubic) unit cell. Porosity
and pore size will be constant.

Small Randomization parameters will

cause an up and down scaling of the
unit cell around the given parameters.
Connection nodes will be kept, so also
the result is one interconnected lattice
structure.

Large Randomization parameters

have been used in this example. One
can see that the unit cells will be less
easy to recognize.

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3. Using the following parameters on our cup example, will result in the following randomization:

The randomized Unit Graph will be used to continue this exercise.

Randomize graphs: Enables the randomization

option of the unit cell
Minimum: The minimal scaling the unit cell will
undergo in order to generate the randomization effect.
Maximum: The maximal scaling the unit cell will
undergo in order to generate the randomization effect.
Trim: Scaling up and down the unit cells, may cause
that the cells get scaled up on the borders, so outside
of your volume. Trim activated will make sure that the
lattice is kept within the given volume after
randomization.

Resulting randomized lattices. The higher the randomization parameters are set, the less the
resulting structure will look like a duplication of a uniti cell.

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9.3. Remove open edges (optional)

Some disadvantages of open lattice beams:
 Can easily break off
 Can be sharp and painful if you touch them
 Don’t contribute to the strength of the lattice structure

Remove open edges

4. Lightweights Toolbar > Filter Graph Function
This function will make new graph groups, based on the selected parameters.

Entity: Graphs that need to be modified

No Connections: All linear beams that don’t have any
neighboring beams on any side are moved into a new
group of graphs.
No and single connections: All beams without a single
connection to another point of the lattice will be moved
to a new group of graphs.

All Filtered beams are positioned in a new graph entity. These can now be selected and
deleted manually. The resulting lattice is a completely closed lattice structure (right picture
below).

5. Select Filtered_New_Graph > RMB > Delete.

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9.4. Assign thickness

In order to produce the actual lattice, a thickness needs to be assigned to the lattice of the
part. This can be done with the function; graph to AM. One will see that the red color of the
graphs will change to a less aggressive color, indicating that the part is printable like this.

Assign Thickness to the lattice

6. Select Lightweights Toolbar > Graph to AM Build

The graph to AM function is a slice based solution and allows you to set all the parameters
needed to send the project to a build processor of Materialise. This avoids the cumbersome
conversion to an STL, which can result in huge data size.

Entity: A part needs to be selected in which the

lattices / graphs will be assigned a thickness to.
Accuracy: Accuracy or triangle size that will be used
in a later phase, in order to generate a solid STL out
of the graph lattices.
The lower this value, the more detailed the lattice but
the more heavy the resulting STL file in the later
phase.
Generating an STL is not obliged if a Build Processor*
of Materialise is used to produce the lattice on an AM
machine.
Thickness Assign the wanted thickness to the graphs
of the indicated part (Entity)
Local AM BP: Graphs that need to have a different
thicknesses as those assigned above, can be added
to via this function. So multiple thicknesses can be
assigned like this. Processing will be done
automatically in a later phase.

Resulting lattice structure is no longer red. A thickness has been applied.

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9.5. Graph to STL

The graph to STL operation allows you to convert the graph design to an STL format. This
can be done for small and medium size models, but for bigger models it’s advised to send
the project to a build processor of Materialise, an extra software which is converting the
graph design to a slice based format for a specific type of 3D printer.

7. Select Lightweights Toolbar > Graph to STL Function

This operation allows to convert all the graphs to STL. When selecting the graph in the STL
Properties, it will show the thickness properties of that particular graph.

When new thickness properties needs to be assigned, the option ‘assign new parameters’ in
Property needs to be selected.

Result:

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The possibilities are endless, here are examples for other parameters:
Unit graph
Structure size 1.8 mm
Thickness 1.00 mm

Unit graph
Structure size 1.8 mm
Thickness 0.2 mm

Unit graph
Structure size 3.2 mm
Thickness 0.2 mm

9.6. Measure porosity

8. Lightweights Toolbar > Porosity Analysis

The porosity analysis measures the void spaces

in a material. For this function the sample region
needs to be selected, because the model with
the graph doesn’t contain the original surface
anymore, the original part is selected.

When clicking apply the porosity measurement will appear in the logger:

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10 Exercise 10: Design a lightweight structure

10.1. Required material
Package & optional modules
- 3-matic Design
- 3-matic Lightweight structures

Files
- [Link]

During this exercise, a filter will be designed with two different types of lightweight structures.
A quad shaped structure on the outer-most surface and the inner-most surface. The middle
volume will be filled by unit structures. In the end all these structures are automatically
connected. The following images show the different lightweight structures created on each
surface and volume.

Figure a. Figure b. Figure c.

The [Link] file contains 4 parts:
Outer surface (figure a): used to make a quad shaped lightweight structure following this
surface
- Inner Quad surface (figure c): used to make a quad shaped lattice structure following this
surface
- Unit structure surface (figure b): used to fill a single unit structure repeated in the volume of
this part
- Top Bottom solid surface: not modified during the project

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10.2. Create Quad Graph

Import the part
1. Select the File menu > select ‘Open Project’ > select the [Link] from the DemoFiles folder

Create Quad graphs

2. In Object Tree > select all parts except the ‘Inner Quad surface’ > right click on one of the selected
parts > select hide.

3. Select the Lightweights toolbar > select the ‘Create Quad Graph’ operation. > Select the ‘Inner
Quad surface’ part > Change the edge length to 5 mm > Select Apply

4. In Object Tree > select the part ‘Inner Quad surface’ > right click on Surface list > Select Empty List

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5. Repeat the same steps for part ‘Outer surface’, but change the edge length to 8 mm.

To view the results of both steps:

6. In Object Tree > select the part ‘Inner Quad surface’ and part ‘Outer surface’ > right click on one of
the selected parts > select show.

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10.3. Create Unit graph

7. In Object Tree > select all parts except the ‘Unit structure surface’ > right click on one of the selected
parts > select hide.
8. Select the File menu > select ‘Import Part’ > select the folder ‘UnitGraphLibrary’ > select [Link]

9. Select the Lightweights toolbar > select the ‘Create Unit Graph’ operation. > Select the ‘Unit
structure surface’ part as entity > open the Object Trees from the part ‘Torque’, and select the
‘Torque’ in the graph set entity box > Select the parameters as shown in the figure below > Select
Apply

A new part is created called ‘Unit structure surface with graph’.

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10.4. Make connections

10. In Object Tree > show ‘Unit structure surface with graph’ and ‘Inner quad surface’ > right click the
selected parts > select show.

11. In Object Tree > open the ‘Inner quad surface’ part tree > open the ‘graph list’ tree > Select
‘Graph_Mantle-0’ and ‘Graph_Mantle-1’ > right click on one of the selected graphs > select merge.

The resulting part is called ‘Graph_Mantle-1’

12. Select the Lightweights toolbar > select the ‘Connect Graphs’ operation. > Select the quad
graph ‘Graph_Mantle-1’ from graph list, of the part ‘Inner quad surface’’ as source graph > Select
the unit structure ‘New Graph’ from graph list, of the part ‘Unit structure surface with graph’ > Make
dense connections between them by selecting 3 connections > Select the parameters as shown in
the figure below > Select Apply

Note that the minimum and maximum connection radius help specify the distance that the
operation will look for in nearest neighboring points on target graph to make connections.

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Result:

13. Repeat same steps for merging the quad graphs of Outer surface (Graph_Mantle-1 and Graph
Mantle-0). Then connect the quad graph ‘Graph_Mantle-1’ from graph list of part ‘Outer surface’
with the ‘New Graph’ of the part ‘Unit structure surface with graph’. But for this case make less
dense connections between them by selecting 1 connection.

Remove unnecessary surfaces and parts. Surface lists of outer surface, inner quad surface,
unit structure surface with graph should be empty. The Torque part should be removed as
well.
14. In Object Tree > select all parts > right click on one of the selected parts > select show.

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10.5. Prepare graphs

Prepare Graph for AM export

15. Select the Lightweights toolbar > select the ‘Graph to AM Build’ operation. > select ‘Outer
surface’ > Assign Thickness of 1.2 mm to indicate the diameter to the graph lines.

16. Repeat above steps with different parameters for ‘Unit structure surface with graph’ part, and ‘Inner
quad surface’ part, as indicated below.

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These parameters can be reviewed via the properties page, for each graph set. For instance,
for the Graph_Mantle_1 for the part ‘Outer surface’:

A 3D view, and slice preview of part in AM software of Materialise, i.e. Magics is as follows:

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Prepare STL from graphs (Optional)

17. Select the Lightweights toolbar > select the ‘Graph to STL’ operation. > Select ‘Graph_Mantle-
1’ and ‘Graph_Mantle-1 to New Graph’ from Object Tree ‘Outer surface’ > Use the following
parameters in Graph to STL build function

This step can be optionally repeated from all graphs to create an STL of all graphs. This step
is not recommended when the design is big and complicated to avoid memory issues. The
recommended step in such cases is Graph to AM build.

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