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Customer Case Studies

Here you will find interesting examples of EOS e-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

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Tooling: Innomia accelerates production and reduces maintenance

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
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Medical: BEGO USA Decides for EOS Technology to Bite Big into Changing U.S. Dental Restoration Market

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 
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Lifestyle Products: Glittering Prospects with Additive Manufacturing of 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.
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Lifestyle Products: Tradition Meets Modernity: Industrial 3D Printing Takes a Turn on the Catwalk

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
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Lifestyle Products: From Pixels to Polymers

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
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Industry: EOS Technology Enables Automation Specialist Festo 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.
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Medical: FHC Switches to 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

 
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Automotive: Easing to Victory – The Rennteam Uni Stuttgart Wins the Formula Student Germany with EOS support

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

 
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Automotive: Electro Racer Made Easy: The Young Engineers of Formula Student Racing are Powering Ahead, Thanks to EOS Technology

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
 
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Medical: If the Climbing Shoe Doesn’t Fit, Design a New Foot

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
 
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Tooling: Plastic Manufacturer FWB Achieves 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 realisa- tion now 25 % more efficient
  • Fast: Final mechanical pro- cessing stage now consists solely of smoothing
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Medical: Saving Cyrano: How 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
  • Biocompatible and resilient: Cobalt chromium material
  • Filigree: small prosthesis with complex design

 
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Medical: EOS Technology Speeds Prototyping and Supports In-House Production Efforts at DePuy Spine

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
 
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Industry: Additive Manufacturing Helps Anubis Go with the Flow (Meter)

Challenge

Production of customized fasteners for a mass flow meter.

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
 
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Lifestyle Products: Sporty Business Start-up Exploits Additive Manufacturing

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
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Lifestyle Products: Cyclists Take Additive Manufacturing for a Spin

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
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Lifestyle Products: Tricky to Play, Easy to Design – Rapid Prototyping for the All New 3D Puzzle Marusenko Sphere

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
 
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Aerospace: Light, Cost and Resource Effective – Researching Sustainability of Direct Metal Laser Sintering (DMLS)

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
 
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Industry: Tangible Success with Additive Manufacturing

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
 
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Tooling: 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
 
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Industry: Full Thrust Ahead: Siemens experiences Innovation for Maintenance of High Performance Industrial Gas Turbines

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
 
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