Case Study: IL Sentiero International Campus reduces gear and sprocket weight with Materialise Magics

Magics’ Honeycomb Structure Keeps the Gears Ticking at the Il Sentiero Campus

Il Sentiero International Campus, a research-focused additive manufacturing campus, needed to make internal test-rig gears and sprockets lighter while ensuring they could withstand high temperatures. The team turned to Materialise Magics and its design for additive manufacturing (DfAM) capabilities to explore a more efficient structure for the parts.

Using Materialise Magics, Mario Franchi created a honeycomb-based design and optimized part orientation and support structures for metal 3D printing in Stainless Steel (AISI 316L). Materialise helped deliver a gear that was 61% lighter, a sprocket that was 53% lighter, and a shaft assembly that was 46% lighter than the standard model, reducing weight and material use while maintaining printability and durability.

IL Sentiero International Campus

Mario Franchi

Application Engineer for Additive Manufacturing