Case Study: KLIO Design achieves lightweight, mass-customizable 3D-printed vehicle parts for smart mobility with Materialise

Smart Design, Smart Mobility KLIO Contributes to South Korea’s Smart Mobility

KLIO Design developed an Open Structure Mobility Concept to showcase at the Seoul Smart Mobility International Conference, aiming to create a small standardized vehicle platform that could accept multiple body designs while maximizing ergonomics, safety and sustainable, mass-customized production. The challenge was to topologically optimize lightweight, stable frames and complex seat geometries without using molds, and to iterate quickly as mounting points and assemblies changed — work that required making organic, 3D-printable parts from NURBS and STL data. KLIO Design worked with Materialise and used Materialise 3-matic (and related Materialise software workflows) to prepare those parts for additive manufacturing.

Materialise helped convert and refine KLIO’s topologically optimized designs into printable STL-level geometry, apply lattice and lightweight structures, split models for printer beds, hollow parts and add powder-escape features, and enable direct output to EOS printers. Using Materialise 3-matic allowed KLIO to edit on an STL level and iterate faster, realize complex organic components that would be impractical with traditional methods, reduce part weight while maintaining strength, and produce the 3D-printed car parts used in the exhibition — demonstrating time savings, easier data handling on regular computers, and effective mass-customization enabled by Materialise.

KLIO Design

Jeongche Yoon

General Manager