Kv schmal

Customer Case Studies

Here you will find interesting examples of EOS Additive Manufacturing technology as applied in practice. Find out how companies have been able to achieve significant business advantages by using EOS solutions.

Please note: We also provide selected Case Studies in French. Please click here -l'étude de cas en français (pdf)!

Choose Category
Aerospace: RUAG - Additive Manufacturing of Satellite Components

Challenge

To develop an extremely lightweight and robust antenna bracket for Sentinel satellites.

Solution

Production of a component using additive manufacturing, which, by virtue of to its complex structures, fulfills all requirements of weight and stability.

Results 

  • Intelligent: freedom of design enables uniform distribution of forces
  • Robust: minimum rigidity requirements exceeded by over 30% 
  • Lightweight: design contributes to a weight reduction of 40%
  • Accredited: requirements of aerospace sector verified by comprehensive testing

More Details
Aerospace: Vectoflow - Additive Manufacturing of probes for measuring speed and temperature in turbo engines

Challenge

To produce robust probes for measuring speed and temperature in turbo engines.

Solution

Additive manufacture of extremely robust and at the same time thin probes featuring a long service life and precise measurements.

Results

  • Flexible: freedom of design in terms of form, material and size
  • Robust: components are up to 150% sturdier than those made by conventional manufacturing
  • Low-maintenance: extended service periods with reduced maintenance overhead
  • Fast: product development in just 1/3 of the usual project duration

More Details
Aerospace: EADS and EOS - Study demonstrates savings potential for DMLS in the aerospace industry

Challenge

Sustainability and cost impact on manufacturing of aerospace parts across the supply chain.

Solution

Use of DMLS to allow the use of different materials, optimised design and more energy efficient processes under consideration of a holistic analysis that included sourcing of raw material.

Results

  • Optimised: improved part design requiring less raw material
  • Sustainable: lower energy consumption over the product lifecycle, resulting in a reduced CO2 site footprint
  • Based on partnership: unique cooperation and continuous improvement of outcomes

More Details
Aerospace: Airbus Defence and Space - Additive Manufacturing process by EOS optimizes Satellite Technology

Challenge

Cost-effective production of optimized retaining brackets for the connection of components in telecommunication satellites.

Solution

Faster production of thermally highly stressed components by using Additive Manufacturing technology for metal parts offered by EOS.

Results

  • Robust: temperature resistance meets high demand of permanent space missions
  • Economic: production costs reduced by more than 20 %
  • Light: weight reduction of the retaining brackets is about  300 g
  • Paving the way: lighthouse project as the pioneering role for other applications in space
 
More Details
Aerospace: Bell Helicopter and Harvest Technologies - Making Production-Grade, Flight-Certified Hardware Using Industrial 3D Printing

Challenge

Design and production of flight-certified components.

Solution

Efficient and resource-conserving production of components for commercial aircrafts using Additive Manufacturing.

Results

  • Optimized: part-integrating capability eliminates assembly costs
  • Efficient: tool-less production saves time and money
  • Fast: clean surface of components reduces post-processing costs and shortens lead times
  • Economical: plastic powder can be recycled

More Details
Aerospace: MTU -  Manufacturing of Engine Components for the Airbus A320neo with EOS Technology

Challenge

Optimised use of the existing EOS machines for the construction of safe and cost-effective series components.

Solution

Additive Manufacturing of borescope bosses for the Geared Turbo Fan of the new engine generation PurePower® PW1100G-JM for the Airbus A320neo.

Results

  • Flexible: Great freedom of design
  • Fast: Development, manufacturing and delivery times considerably reduced 
  • Economical: Low use of matrial and tools in manufacturing drastically reduces costs of development and production

More Details
Automotive: Formula Student Germany – EOS supports racing team by producing a topology-optimized steering stub axle

Challenge

Build a reliable, lightweight axle-pivot with high rigidity, in the shortest possible time.
 

Solution

Production of a topology-optimized steering stub axle using EOS technology.
 

Results

  • Optimized: perfect form and contouring for a reduced weight by 35% and an increased rigidity by 20%
  • Speedy: significant shortage in development and production time
  • Safety: reliable on the track

 
More Details
Automotive: Formula Student Racing - Additive Manufactured lightweight battery housing for an electric-powered race car

Challenge

Build in the shortest possible time, a lightweight, compact battery housing with integrated cable ducts and cooling channels for an electric-powered race car.
 

Solution

Production of the battery housing from fire-resistant PA12 material, using Additive Manufacturing.
 

Results

  • Optimised: lightweight and compact for weight and volume savings
  • Construction freedom: integrated cooling channels and cable ducts
  • Safe: fire-resistant material


More Details
Automotive: Formula Student – Improved Cooling Thanks to Aluminum Jacket with Internal Helix-Structure Produced with DMLS

Challenge

Design and production of a function-integrated cooling water jacket, that dissipates heat directly at the electric motor creating it.
 

Solution

Additive Manufacturing of different test components from polyamide as well as of the final component with integrated cooling channels using the EOS M 290. 
 

Results

  • Functional: Integration of cooling and transmission/wheel mounts in a single component
  • Lightweight: 16% weight reduction improves performance
  • Effective: Increase in cooling performance by 37% compared to the previous season's car

 
More Details
Automotive: DHBW Engineering - Cooling System for Race Car Produced with the EOS P 396

Challenge

Build a high-performance cooling unit for a Formula-Electric car, which is integrated in the battery container of the vehicle. 
 

Solution

Additive Manufacturing of a component to dissipate cooling air using the EOS P 396.

Results

  • Lightweight: reduction of the component weight by 80% to just 77g
  • Functional: design allows for the fast servicing of safety-relevant parts
  • High performance: well over twice the cooling performance when compared to the previous year's car
 
More Details
Industry: APS Technology - Oilfield drilling equipment manufacturer uses industrial 3D-printing technology from EOS 

Challenge

To make oilfield drilling equipment even more durable and flexible using additive manufacturing.

Solution

The EOSINT M 280 makes it possible to build more complex drilling equipment, that even withstands in the harsh environment of oil and gas wells.

Results 

  • Optimized: drilling assembly with part count reduced from four separate components to just one
  • Efficient: optimized design increases drilling accuracy, reduces post-processing and production costs
  • Fast: shorter lead times and times to market
  • Profitable: no need for moulds and the production time involved


More Details
Industry: Anubis 3D - 3D-printed end-of-arm for smarter packaging

Challenge

Bulding a lighter, yet more powerful vacuum gripper for a major American food producer's equipment supplier.

Solution

With EOS systems, it was quite easy to build a lighter and even more powerful tool that enables for smarter packaging.

Results

  • Efficient: 500g light gripper has four times the power 
  • Fast: new tool was ready to use in just one week 
  • Tweaked: less parts make assembly very easy 
  • Flexible: freedom of design enables optimized production processes 

More Details
Industry: Beta LAYOUT - Multi-dimensional circuit carriers using additive manufacturing

Challenge

To produce individual prototypes for circuit carriers.

Solution

Component made through additive manufacturing that is given functionality after production via laser direct structuring.

Results

  • Simple: access to advanced technology for research and development 
  • Economical: tool-free production reduces costs 
  • Customized: service provider of tailor-made products


More Details
Industry: Euro-K - 3D printed micro-burners for the optimized combustion of gaseous and liquid fuel

Challenge

Develop and build a multi-fuel burner capable of using gaseous and liquid fuels.

Solution

Additive Manufacturing of a burner with an optimized footprint and functionality on the EOS M 290.

Results

  • Flexible: can use gaseous and liquid fuels
  • Profitable: integral functionality allows fuels that are difficult to burn to be used
  • Efficient: 20% reduction in the size of the combustion chamber
  • Economical: low unit costs despite small batch sizes
  • Environmentally effective: reduces nitrous oxide emissions


More Details
Industry: ASS Maschinenbau - Additively Manufactured Robotic Hand for Pharmaceutical Supplier Theo Hillers GmbH

Challenge

Design and construct an extremely light, functionally integrated gripper for the removal of sieves for the pharmaceutical industry.

Solution 

Manufacture of a lightweight robotic hand with integrated air channels from polyamide using the EOSINT P 390.

Results 

  • Light: low weight through utilization of polyamide and integration of functions
  • Increases quality: less wastage in the working process
  • Uncomplicated: integrated construction with reduced complexity and shorter assembly time
 
More Details
Industry: Anubis - EOS Solution and materials provide low costs, high quality, and quick turnaround times for flow meter parts

Challenge

Production of r.

Solution

Fast development of the frame-work design and inexpensive production of the parts in small series with a FORMIGA P 100.

Results

  • Design flexibility: unique frames to hold delicate electronic components
  • Evolutionary: technology enables continuous testing and optimization of parts
  • Economic: rapid product development at low costs
 
More Details
Industry: Festo - Additive Manufacturing Enables Automation Specialist to Design its Bionic Assistance System

Challenge

Production of a bionic gripper that can reliably pick up and safely put down objects gently and flexibly.

Solution

Fast and economic small batch production of complex components using a FORMIGA P 100 supplied by EOS.

Results

  • Optimized: Function integration reduces the number of single parts and the expenditure for assembly.
  • Flexible: Thanks to the high degree in design flexibility, the design determines the production method.
  • Economic: Innovative manufacturing method makes grippers light-weight and long-lasting.
  • Efficient: Tool-less production saves time and money.
  • Profitable: Laser sintering has arrived in industrial production environment.

 
More Details
Industry: Siemens - EOS Technology opens up new opportunities for industrial gas turbine maintenance cost reduction

Challenge

Customizing an EOS solution for the precise, cost-effective, and faster repair of gas turbine components exposed to extreme temperatures.

Solution

Enlargement of the construction capacity to accommodate individual customized repairs through the reapplication
of material to the worn burner tip of the gas turbine.

Results

  • Fast: time required for the repair process of burner tips has fallen by more than 90%
  • Innovative: old burner versions can quickly be brought up to the latest standards of technology
  • Cost-effective: potential cost reductions already seen at an early stage
 
More Details
Industry: Wittmann Group - EOS additive manufactured lightweight grip system with integrated functionality

Challenge

Build a lightweight grip system with integrated functionality capable of moving the required loads over a minimum of 5 million operating cycles.

Solution

Simplified design and small-series production of stable grippers on a functional base plate utilizing a FORMIGA P 100.

Results

  • Light: 86% weight reduction to just 220 g
  • Economical: production costs reduced by 50%
  • Fast: manufacturing time shortened from twelve to three days
  • Optimized: functional integration, reduced assembly costs, and number of individual components down from 21 to just two
 
More Details
L'étude de cas en francaise (pdf)
Lifestyle-Products: Bobby Tailor - Custom-made Bobby Cars with Additive Manufacturing

Challenge

Economically manufacturing of high-grade components for luxury Bobby Cars.

Solution

Batch-size adjusted additive manufacturing of components and tools using EOS systems.

Results

  • Customized: The ability to quickly produce one-off pieces that fulfil customers' desires
  • Cost awareness: Series production of small batch sizes 
  • Empowering: AM technology as the basis for an entire business model

More Details
Lifestyle-Products: Canto - Innovative manufacturing technology for the perfect dive light

Challenge

The development of a robust dive light with a bayonet connection from PA 2200 with functional integration.

Solution

Additive manufacture of a particularly stable and at the same time lighter weight plastic connector with greater functional integration using the FORMIGA P110.

Results 

  • Optimized: functional integration reduced the number of individual components
  • Stable: waterproof plastic PA 2200 withstands extreme stresses at great dive depths
  • Weight reduction: metal components were replaced with plastics
  • Flexible: economical production even with small batch sizes

More Details
Lifestyle-Products: New Balance - Improved runner performance with EOS industrial 3D-Printing Technology

Challenge

Helping athletes become faster on the track by personalising a runner’s shoes

Solution

Additive Manufacturing of customised spike plates for competition using an EOSINT P 395

Results 

  • Tailor-made: ideal and customised fitting
  • Light: reduced weight for minimised load and better performance
  • Fast: production of several models within a short period of time
 
More Details
Lifestyle Products: Hoet - Additive Manufacturing of eyeglass frames out of titanium

Challenge

To produce an eyewear series with specific design characteristics that meet the precise demands of the client.

Solution

Additive Manufacturing of eyeglass frames with a honeycomb structure made of titanium using the EOS M 290.

Results

  • Attractive: new design possibilities
  • Customized: ease and cost-effectiveness of producing tailor-made products  
  • Sustainable: eradication of production surpluses frequently encountered in the industry


More Details
Lifestyle Products: LUUV - Innovative Camera Mount Produced by Additive Manufacturing

Challenge

To make a housing for a low-price engineering prototype or low-price small series.

Solution

Production of a jacket housing for a camera stabilizer mount with a FORMIGA P 110.

Results

  • Faster: short production times using rapid prototyping
  • Requirement-oriented: just-in-time production
  • Flexible: production also possible in low run numbers
 
 
More Details
Lifestyle Products: Kappius Components - Design and manufacturing of highly complex bike hubs with EOS additive technology

Challenge

Design and manufacture highly complex hubs which transfer more power from pedal to wheel.

Solution

Produce innovative and extremely durable drivetrains for cyclists with an EOSINT M 270.

Results

  • Racy: optimized hub design increases drive force
  • Innovative: design determines production method and not vice versa
  • Economic: rapid product development makes two-person company competitive
  • Indestructible: maraging steel withstands high loads

 
More Details
Lifestyle Products: LCAD - 3D Printing of a complex mask with EOS Additive Manufacturing Technology

Challenge

Bringing virtual computer game characters to life with the help of 3D printing.

Solution

Production of a complex mask of a character from a computer game via an EOSINT P 700-series system.

Results

  • Accurate: exact copy of the intricately detailed structure of the object
  • Collaboration: cooperation between an educational institution and a company to provide students with innovative technology

 
More Details
Lifestyle Products: Cooksongold - EOS developes Additive Manufacturing technology capable of series production for gold

Challenge

Develop a new way of Direct Metal Laser Sintering (DMLS) that is suitable for the physical properties of gold.

Solution

Successfully establish a new technology capable of series production offering a high degree of design flexibility.

Results

  • Optimized: specially built laser optics and raw material
  • Sustainable: less raw material required
  • Creative: completely new possibilities for designers
  • Together: DMLS as a service resulting offering a high degree of design flexibility.

 
More Details
Lifestyle Products: RaceWare Direct - Profitable production of durable plastic and metal bicycle accessorie with EOS 3D Printing

Challenge 

Speedy design and manufacturing of customized cycling equipment made of plastic and metal.
 

Solution 

Profitable production of durable bicycle accessories in small and very small series with EOS systems.

Results 

  • High quality and robust: Mounts pass hardness test
  • Economical: no upfront costs thanks to tool-less production
  • Speedy: quicker product development and delivery
  • Cost effective: outsourcing of manufacturing keeps investment costs low

 
More Details
Lifestyle Products: 3D Printshow - Additive Manufacturing of wearable and sophisticated haute couture

Challenge

 Creation of a delicate and complex headdress by means of Additive Manufacturing.

Solution

Manufacturing of wearable and sophisticated haute couture using an EOSINT P 760.

Results

  • Creative: artists can focus on the design - rather than the production process
  • Premium: surface finish and consistency of the polyamide powder correspond to an artist’s demand for high quality

 
More Details
Lifestyle Products: Marusenko – EOS Technology enables Rapid Prototyping for new 3D Puzzle

Challenge

Build fully functional prototypes for an all new 3D puzzle for preparing batch fabrication.

Solution

Quick manufacturing of stable prototypes that enable a correct movement of the components by using a FORMIGA P 100.

Results

  • Optimized: fully working prototype
  • Flexible: made all the adjustments that were needed
  • Economical: ease prototyping phase, optimize product for batch production
  • Speedy: produce several prototypes for the International Puzzle Design Competition


More Details
Medical:  plus medica OT - Maximum Flexibility and Design Freedom in the Production of Orthoses

Challenge

Design, CAD engineering and production of orthoses that combine several functions, optimally tailored to the needs of the patient

Solution

Construction of individually tailored orthoses for patients, using industrial 3D printing performed with the EOS P 396

Results

  • Functional: complete freedom of design for structures, functions and material thicknesses
  • Comfortable: low weight and breathability enhance wearer comfort
  • Reproducible: once developed, any particular orthosis can be produced again at any time with the same structure
  • Standardised: consistent and repeatable production quality with no dependence on manual production quality factors, personnel qualification and technical facilities
  •  
More Details
Medical: Alphaform - Production of hip implant by using Additive Manufacturing

Challenge

Design and construct a precision-fitting, lightweight, yet stable hip implant in a short period of time.

Solution 

Manufacture of a lightweight titanium implant made with the EOSINT M 280 and integrated into the cavity.

Results 

  • Fast: Short planning and production times for an imminent operation
  • Light: Minimum weight for minimal patient limitations
  • Precise: Exact fit for the best possible alignment to the skeleton

More Details
Medical: University of Michigan - Customizing a biocompatible material for additively manufactured medical implants

Challenge

To build life-saving, patient-specific implants from a resorbable material by means of Additive Manufacturing.

Solution

A research collaboration between the University of Michigan, its associated hospital, and EOS, based on the use of a FORMIGA P 100.

Results

  • Individual: patient-specific splints for children of all ages
  • Economical: cost-effective, even in small quantities
  • Fast and automatic: from design to print within two days

More Details
Medical (Dental): BEGO USA - Patient specific restorations made of a high-performance alloy

Challenge 

Economic production of patient specific restorations made of a high-performance alloy. 
 

Solution 

Manufacturing of fully dense restorations without porosity by using an EOSINT M 270. 
 

Results

  • Economic: fast and cost-efficient manufacturing 
  • Precise: provided accuracy of the units is +/- 20 microns 
  • High-class: restorations are durable, capable and have a consistently good quality

More Details
Medical: DePuy Spine - EOS Additive Manufacturing Technology speeds prototyping of complex surgical tools

Challenge

Accelerated development of medical instruments according to the consulting doctors’ requirements.

Solution

Speedy and flexible manufacturing of complex surgical tool prototypes using an EOSINT M 270.

Results

  • Speedy: delivery times for surgical tool prototypes have shrunk from several months to less than a week
  • Innovative: designing for functionality not for manufacturability
  • Flexible: CAD design of instruments easy to adjust to the consulting doctors’ requirements
  • Economic: In-house production safes time and money
 
More Details
Medical: FHC - EOS Technology for Manufacturing of Stereotactic Platforms for Neurosurgery

Challenge

Manufacturing of STarFix patient-matched frameless stereotactic fixtures.
 

Solution

Small-batch production of precision surgical components using a FORMIGA P 100.


Results

  • Comfort and care: customized design fosters patient well-being and shortens OR time
  • Precision: highest-quality production to strict standards required for medical applications
  • Improved functionality: parts consolidation resulting in simpler designs with more features
  • Economic: uses less material, provides faster manufacturing turnaround times

 
More Details
Medical: Morris Technologies - Lightweight climbing prosthesis made of titanium by EOS Additive Manufacturing

Challenge

Develop a lightweight but stable prosthesis for a disabled climber. 
 

Solution

Production of an individual climbing prosthesis made of titanium by using Additive Manufacturing. 
 

Results

  • Optimised: material and hole production for an ideal compromise between low weight and high stiffness
  • Personalised: prosthesis is customised to one’s individual anatomy and purpose
  • Freedom of design: EOS technology is disrupting conventional manufacturing methods
 
More Details
Medical: NC State University - How EOS Additive Manufacturing helped create a one-of-a-kind knee joint for a cat

Challenge

Developing customised leg prosthesis for a cat after successful cancer treatment.
 

Solution

Manufacturing of prosthesis with surface structures that promote bone ingrowth.


Results

  • Versatile: surface structure depends on the intended use
  • Customised: design of the prosthesis considers bone condition
  • Excellent mechanical properties and resilience: Cobalt chromium material
  • Filigree: small prosthesis with complex design

 
More Details
Medical: OPM - Additive Manufactured Cranial Implants Offer Improved Patient Outcomes at Reduced Surgical Costs

Challenge

Production and FDA approval of patient-specific polymeric cranial implants based on CT or MRI scans.

Solution

Speedy manufacturing of individual cranial implants made of PEKK on an EOSINT P 800 by EOS.

Results

  • Customized: fewer side effects due to patient specific manufacturing 
  • Osteoconductive: bone cells grow into PEKK implant and increase its long term stability 
  • Integrated: self-contained production and supply chain

 
More Details
Medical (Dental): Argen Corporation - EOS Technology allows daily turnout of hundreds of units

Challenge

Economic production of patientspecific restorations made of a high-performance alloy.

Solution

Accurate and efficient manufacturing of crowns and bridges using an EOSINT M 270.

Results

  • Economic: digital manufacturing saves time and money
  • Premium: restorations are durable, capable and demonstrate consistently good quality
  • Precise: units show constant accuracy
  • Efficient: dental labs increase their product offerings and boost productivity
 
More Details
Medical: CEIT Biomedical Engineering - Precise implants for cranial, jaw, and facial bones using Additive Manufacturing

Challenge

Provision of technology and material for the production of precision implants for cranial, jaw, and facial bones using Additive Manufacturing.

Solution 

The manufacture of customized, patient-specific implants from biocompatible titanium alloy, using the EOSINT M 280.

Results

  • Patient-specific: form precision of the implant leads to reduced side-effects
  • Efficient: lower error-rate during production and constant manufacturing costs with increased precision
  • Innovative: use of lattice structures promotes the in-growth of bone tissue and allows for integration of micro-sensors
  • Approved: implant has been registered by the Slovakian State Health Authority (SIDC)

More Details
Medical: Alphaform - Precision-fit cranial implants produced with Additive Manufacturing by EOS

Challenge

Development and manufacture of a precision-fit implant for the cranial area with particular permeability for liquids and heat dissipation.

Solution 

Manufacture of a highly stable, yet porous, cranial implant using the EOSINT M 280.

Results

  • Optimized: permeable for liquids, protects against heat 
  • Stable: large-scale implant despite porous structure
  • Innovative: lattice structures support the attachment and in-growth of bone tissue
 
More Details
Tooling: Salcomp - Additive Manufacturing Permits Optimized Cooling for Maximum Production Efficiency

Challenge

Optimize the cooling system design for the production process of plastic parts to make precision cooling become a reality.

Solution

Develop an improved cooling design and manufacture new core inserts using Additive Manufacturing.

Results

  • Greater efficiency: production increased by approx. 56,000 units/month
  • Cost-saving and sustainable: rejection rate reduced from 2% to 1.4%
  • Economic: annual cost savings of approx. 20,000 euros
 
More Details
Tooling: Innomia  - Czech Tool Manufacturer Relies on Additive Manufacturing for Complex Customer Projects

Challenge

To optimize the cooling process for manufacturing, arm-rests for automobile construction. Reduce the production cycle period, improve component quality and increase maintenance intervals.

Solution

Construction of precision cooling channels in injection mold tool and manufacturing of the optimized core using the EOSINT M 270.

Results

  • Reliability: production plant maintenance extended from every two weeks to every five or six
  • Quality: uniform cooling prevents deformation of the plastic end product
  • Costs reduction: Costs are lowered through a 17% cut in cycle times for the plastic injection moldings

More Details
Tooling: FWB - Major Savings in Production Time and Cost Using Additive Manufacturing

Challenge

Cost-optimised production of mould inserts for injection-moulded tools in serial production.

Solution

Replacement of hybrids with mould inserts produced by a fully additive and considerably more time-and-cost-efficient process, using an EOSINT M 280.


Results

  • High-precision: Entire production of inserts using laser sintering technology
  • Time-saving: Production time reduced by four weeks
  • Economic: Component realisation now 25 % more efficient
  • Fast: Final mechanical processing stage now consists solely of smoothing

More Details
youtube linkedin xing