Case Study: Korea Aerospace Research Institute (KARI) achieves lightweight, printable lattice aerospace parts with Materialise 3-matic

KARI Optimizes and Converts 3D Lattice Design with DfAM Process and Materialise 3-matic

The Korea Aerospace Research Institute (KARI) needed to further reduce weight on a landing-gear component by converting OptiStruct topology-optimized results into a lattice-structured, printable STL while preserving structural integrity. Conventional CAD and their service bureau could not smooth the topology, control the lattice, or prevent support material from fusing with the lattice, so KARI engaged Materialise and its Materialise 3-matic software and DfAM expertise to address the challenge.

Materialise provided 3-matic plus dedicated DfAM training and engineering support (including guidance from product expert Kim Dongho) to optimize the topology, calculate surface area, set build orientation, and add thin solid downfacing layers to protect the lattice during printing. The Materialise solution converted the model into a print-ready STL, avoided lattice breakage, enabled simulation verification and successful metal 3D printing, reduced trial-and-error, and delivered a lighter, more reliable part—prompting KARI to launch another project with Materialise 3-matic.

Korea Aerospace Research Institute

Kim Tae-Wook

Korea Aerospace Research Institute