Case Study: Altair achieves topology-optimized, 3D-printed titanium spider bracket with Materialise

The Spider Bracket A Topology Optimization Project by Altair, Materialise, and Renishaw

Altair set out to develop an R&D “spider bracket”: a topology‑optimized, organically shaped connector with hybrid lattice regions intended for architectural glass assemblies. The complex, edgy geometry produced by Altair’s optimization created irregular interfaces between solid and lattice zones, risked stress concentrations and lattice breakage during support removal, and resulted in an unwieldy multi‑gigabyte file that threatened printability for metal AM. Materialise was brought in to ready the part for production using its software and services.

Materialise used 3-matic to smooth and reconstruct the rough topology, added thin solid layers under supported lattices, and employed Magics (including the Support Generation Module) and the slice‑based Build Processor to optimize orientation, supports and file handling. The collaboration—together with Renishaw for machine build—allowed the nearly 4 GB dataset to be converted into a printable build file and produced a titanium spider bracket that preserved the lightweight, strong characteristics of Altair’s design while minimizing deformation and support-related damage. Materialise’s workflow made an otherwise unprintable geometry manufacturable and repeatable.

Altair