Case Study: Atos achieves 66% weight reduction and accurate deformation prediction with Materialise's simulation software

Predicting Deformations of Titanium Inserts The Power of Simulation Software

Atos developed a lightweight titanium insert for aeronautic sandwich panels—achieving a 66% weight reduction versus a traditional brick-like design—but faced significant additive-manufacturing challenges. The large (366 × 171 × 92 mm), cellular insert is prone to thermal gradients, residual stresses and shrinkage during metal 3D printing that can cause local and global deformations, cracks and costly failed builds (around €2,500 per part). To address this, Atos worked with Materialise using its Magics simulation software to predict and mitigate those risks.

Materialise calibrated the Magics simulation to the machine and material, sliced and meshed the CAD, applied machine-specific eigenstrains layer-by-layer, simulated support and base-plate removal, and compared the simulated deformations to 3D-scanned measurements of the printed part. Materialise’s simulations matched the measured deformations closely, identifying both local and global problem areas and enabling design/process optimizations that increase first-pass success and protect against expensive failures—demonstrating that Materialise’s simulation workflow can reliably predict and help prevent AM part deformation.

Atos