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Welcome 3

Product Overview 4

Measuring Fixtures 6

Checking Fixtures 8

Calibers & Hand Applies 10

Measuring Accessories 12

Cubing Technology 14

Project Flow 18

Standard Solutions 20

Laser Sintering 22

Additive Manufacturing 24

Material Specifi cation 26

Manufacturing Process 28

Quality Control 30

Retooling 32

Materialise background 34

Welcome to the Factory for 3D Printed FixturesEver since its start in 1990, Materialise has been playing a pioneering role in the fi eld of Additive Manufacturing (AM, also known as 3D Printing). In addition to our solid reputation as a provider of software and innovative solutions for 3D Printing, we are known for running one of the largest printing equipment facilities in Europe.

RapidFit+: a system that changes how fi xtures are designed and manufactured. As a modular system, RapidFit+ off ers a high degree of customization and accuracy while also allowing for the re-use of standardized elements. Advanced functionality can be integrated into the fi xtures, such as snap-fi ts and clips. These in turn enable increased repeatability and a better representation of the part environment. RapidFit became a “game changer” in Automotive tooling, shortening the time to market for your product.

Your fi xture specifi cation

Design & Engineering

Additive Manufacturing

Assembly & Certifi cation

Your certifi ed inspection fi xture

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The Benefi ts of the RapidFit+ System:

- Easy modifi cations and quick turn-around for new iterations. Being modular, RapidFit+ delivers a highly adaptable and partially re-usable system, leading to long term savings.

- The system makes use of the latest and fi nest Additive Manufacturing technology, allowing limitless freedom of design.

- The integration of functionality like clips and snap fi ts.

- Ergonomic: fi xtures that are 50% lighter.

Discover the Next Generation of Metrology Fixtures

Measurement fi xtures Gauges & SPC gauges Calibers & Tools Cubing Systems Measuring Accessories

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Measuring FixturesDue to the special capability of 3D printing, fixtures can be equipped with special features (functionalities). The RapidFit+-Program to print components provides standardized options for integrated functionalities.

Very often Automotive workpieces have latches and clips in order to ease the assembly process of a car. These situations will be simulated by holding-functionalities in order to reproduce the original mounting condition during quality inspection. E.g. adaptors to simulate the sheet metal part into which the part will be clipped.

Optical fixture for IP parts Clip fixture for panel

Example: clip release for Omega clips

Advantage :- Complex technical requirements translated

into a standard 3D printed solution.- Best possible simulation of environment- Steel inserts guarantee long lifetime- Use friendly through simultaneous clip eject

FastFacts

Inteligent: Integrated functionality

Fast: Additive Manufacturing

Efficient: Complex Geometry made simple

Ergonomic: Easy attachment and release of parts

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Checking Fixtures & SPC GaugesCreate quality inspection fixtures faster than ever thanks to the latest innovations by RapidFit+.

RapidFit+ sets a new standard in the production of test equipment with the introduction of 3D-printed contour blocks. These blocks are more efficient, lighter and faster to produce because they do not rely on conventionalproduction methods – e.g. milling a complete block of aluminum or using cast aluminum. What’s more, the end result remains the same - quality test equipment for quality control that you can count on.

To produce these fixtures, RapidFit+ uses an innovative material and 3D Printing to create the final form simulators, achieving an accuracy of +/- 0.1 mm aftermechanical finishing.

FastFacts

Complex fixtures made easy: The use of standard solutions from our parametric library reduce your time to market

Additive-manufactured parts + post-machining process result in supreme surface quality

Efficient: only print what is needed

Weight & strength optimized

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Calibers & Hand AppliesAny three-dimensional shape, which often cannot be manufactured with conventional mechanical machining methods, can be manufactured. The jigs serve as a lightweight, accurate hand tools to quickly check specific positions or shapes. As several contours can be made simultaneously, the entire fixture building process is considerably speeded up.

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FastFacts

Light: ergonomic handling of tools

Fast: 3D printed and standard components

Functional: intelligent solutions can be incorporated

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Measuring Tools & AccessoriesExterior target frame for the optical 3D scanning of objects. Made from carbon fiber beams and 3D-printed joints and target pods, this lightweight, strong, and impact-resistant structure can easily be adapted for different part sizes. In addition, it is cost-efficient compared to aluminum target frames and addresses some of the issues that arise from using target stickers for optical scanning.

FastFacts

Leightweight: Ergonomic and fast assembly and use.

Fast: Additive Manufacturing.

Efficient: No reference markers required on the workpiece itself.

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RapidFit Cubing System

Cubing Technology

FastFacts

Reduce amount of tools

Reduce development tooling cost

Reduce time requirements

Modular: easy exchange and update of separate modules

Efficient: only critical area’s simulated

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Part

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Production Fixtures

RapidFit Fixtures

Development Fixtures

RapidFit Smart Cube

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Vehicle development Quality ToolingClay Model

Surface Release Model

Prototype Assembly Buck

Matching / Blue Buck

E-Cube

Styling Process Engineering Process Production Process

FastFacts RF Smart Cube

One single tool to cover all design stages and tool functions

No compromise in quality verfi cation

Low cost of changes for CAD updates

Enabler to speed up vehicle development process

FastFacts RF Fixtues

One single fi xture used for prototype and production stage

Fast delivery of prototype fi xture, which will volve to high-end production fi xture

No compromise in quality verfi cation

Tool Release Model

The automotive industry uses all kinds of fi xtures, development bucks, cubings and many more for the assessment of fi tting accuracy of single parts and assemblies. RapidFit proposes a single cube to combine many of the functions of these diff erent expensive tools: the RapidFit SmartCube. The SmartCube allows you to build a cube in a very early design stage, and let it evolve with CAD updates. A low cost for changes is intrinsic to our approach: only a few printed elements are to be replaced, and this update can be performed off -line – the cube stays at you disposition at all time.

The same principle is applied on single component fi xtures: the prototype checking fi xture can evolve into a production gauge.

FastFacts

No compromise in quality verfi cation

Single design updates will be incorporated in one tool

Enables diff erent teams to work together at the same place

Reduced time requirements

Low cost of changes

With the RapidFit Smart Tooling, the standard basic structures components as well as the 3D printed locators and contours can be adapted to changing requirements anytime, anywhere .

RapidFit enables you to speed up your engineering and development process.

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Project FlowWorking With You, from Concept to Certifi cation

Requirement Defi nitionRapidFit+ starts the design process bylistening to you and discovering yourspecifi c needs. Each fi xture is customizedto make it easier for you to accuratelymeasure and check the quality of yourparts.

Design ProcessThe fi xture’s design is customized to meetyour specifi c needs and is optimized forAdditive Manufacturing using Materialise’smarket-leading software.

AM ProductionThanks to software developed in-house,like Magics and Streamics, the designsthat are prepared and sent to productionget the most out of Additive Manufacturingin terms of effi ciency, accuracy and quality.The fi xtures are produced using top-of-the line Additive Manufacturing equipment andmaterials.

AssemblyAssembly is done in a temperature-controlled environment by in-house assembly experts.

Certifi cationCertifi cation and calibration are done in atemperature-controlled lab environment,ensuring a high-quality, accurate result.

AM Production Assembly Certifi cationRequirement Defi nition Design Process

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Our Standard Solutions

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Understanding the client’s needs & expectations

Align on specifi cations 3D printed standard solutions Fully understand the fi xture and its functionalities

RapidFit+ introduces a new workfl ow: already at the proposal stage, RapidFit shows which of our standard solutions is proposed for each feature of your parts. This gives you a clear idea from the start of how your fully customized fi xture will look.

This new workfl ow is made possible through the consistent standardization of RapidFit+ solutions.

FastFacts

Clear presentation of solutions for your component at quotation stage

Clear defi nition of the locator and clamping situation

Faster project fl ow

Lower costs through standardization

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Laser Sinteringis the Ideal Solution for:

- Fully-functional prototypes with mechanical properties comparable to those of injection-molded parts- Series of small components- Large and complex functional parts up to 700 x 380 x 580 mm in one piece- Personalized Manufacturing, i.e. the production of unique, complex, personalized designs built as one-time-only products or in small batches

Good Reasonsto Choose Laser Sintering:

- Fast- Builds durable and functional parts- Suitable for large and complex parts- Design freedom (no support structure necessary)- Wide range of finishing degrees- Can be sealed watertight

Lase

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A laser binds powder particles together

Successive powder layers are spread on top of each other

Powder removal and part finishing

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Add

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FDM is the Ideal Solution for:- Prototypes for functional testing- Prototypes for form and fit testing- Small series production- Prototypes directly constructed in production materials- Quality parts with a high stability- Durable, individual parts up to 900 x 600 x 900 mm

Laser Meltingis the Ideal Solution for:- Fully functional prototypes- Production tools- Molds and inserts- Rigid housings- Ductwork- Spare parts- Heat exchangers

Stereolithographyis the Ideal Solution for:- Parts with smooth surfaces and fine details- Visual prototypes for photo shoots, market testing and design verification- Prototypes for limited functional testing- Masters for copying techniques (Reaction Injection Molding & Vacuum Casting )- Mimicking metal components using a metal plating process- Low-volume production of complex geometries

Selective Laser Sintering Fused Deposition Modelling

Material & Technology PA, Selective Laser SinteringHardness 75 Shore DFlexural modulus (stiffness) 1250 MPaFlexural strength 48 MPaHeat Deflection Temp 86° CFinishing Smoothing by rotary vibrationAccuracy 0.1mm for small parts (<100x100x100mm) 0.2mm for bigger parts (>100x100x100mm and <200x200x200cm)Application Standard solution for locators Integrated functions are possible

Material & Technology ABS, Fused Deposition ModellingHardness Rockwell R105Flexural modulus (stiffness) 1834 MPaFlexural strength 41 MPaHeat Deflection Temp 96° CFinishing Vapour smoothing machineAccuracy 0.1mm for small parts (<100x100x100mm) 0.1mm for bigger parts (<500x500x500mm) Application Integrated functions are possible Ideal for contour parts and hybrid cubings for testing fixtures

Material & Technology PA-GF, Selective Laser SinteringHardness 80 Shore DFlexural modulus (stiffness) 2100 MPaFlexural strength 74 MPaHeat Deflection Temp 110° CFinishing Smoothing by rotary vibrationAccuracy 0.1mm for small parts (<100x100x100mm) 0.2mm for bigger parts (>100x100x100mm and <200x200x200cm)Application Solution for impact testing Solution for climate (temperature & humidity) testing

Material & Technology PC, Fused Deposition ModellingHardness Rockwell R115Flexural modulus (stiffness) 2137 MPaFlexural strength 97 MPaHeat Deflection Temp 127° CFinishing Vapour smoothing machineAccuracy 0.1mm for small parts (<100x100x100mm) 0.1mm for bigger parts <500x500x500mm Application Integrated functions are possible Ideal for contour parts and hybrid cubings for testing fixtures

Material & Technology Alulon, Selective Laser SinteringHardness 76 Shore DFlexural modulus (stiffness) 3000 MPaFlexural strength 74 MPaHeat Deflection Temp 130° CFinishing Smoothing by rotary vibrationAccuracy 0.1mm for small parts (<100x100x100mm) 0.2mm for bigger parts (>100x100x100mm and <200x200x200cm)Application Solution for impact testing

Mat

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Print Tolerance: +/- 0.15 to +/- 0.20 mm (Depending on the Complexity of Part and Layer Thickness)

Machine Tolerance Adjusted to: +/- 0.05mm

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RapidFit ProductionFor checking contours and gaging parts Materialise has developed a material-composition of Aluminum and Polyamid. Contour parts can be build up to 700 millimetres in one piece, which combines the specific advantages of both materials: lightweight, stiffness and long-term stability.

Additionally, this material can be post-machined when an accuracy better than +/- 0.5mm is required. Final result after post-machining is +/- 0.1mm or +/- 50mu, depending on requirements and size of the fixture/gauge.

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FastFacts

Nikon LK HC 90, large horizontal CMM

Nikon, LK V, high accuracy Portal CMM

GOM Artos, White light laser scanner

GOM Tritop, Photogrammetry

Climatized Measuring Room Class 3

RapidFit Quality Control

The highest standards in the industry.

The measuring capacity for your parts at your door step. Our high standards ensure the accurate and fast measuring service.

Tool Lifecycle Management (TLM) / Retooling

In order to ensure that our methods are cost-eff ective, RapidFit+ is reusable.

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RapidFit off ers a complete service solution, which includes:

Initial concept & design

Manufacturing and certifi cation of fi xtures

Yearly maintenance & re-calibration

Decommissioning & retooling

We can reuse your equipment for future fi xtures

Ergonomic: fi xtures that are 50% lighter

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16 Offi ces Worldwide

2000+ Printed parts per day

1.300+ Employees

95 Patents Granted

165Patents Pending

130+ 3D Printers

8000 Installed software licenses

Materialise in Numbers

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About Materialise: With its headquarters in Leuven, Belgium, and branches worldwide, Materialise has been playing an active role in the fi eld of Additive Manufacturing (AM) since 1990. In addition to having the largest single-site capacity of AM equipment in Europe, Materialise also enjoys a stellar reputation as a provider of innovative software solutions. They have used their experience and expertise to create a better and healthier world through their involvement in AM for industrial and medical applications, and by providing bio-medical and clinical solutions such as medical image processing and surgical simulations.Materialise has developed unique solutions that make a world of diff erence for its many customers with their prototyping, production, and medical needs. These customers range from large companies in the automotive, consumer electronics, and consumables sectors; to famous hospitals, research institutes, and clinicians; to individual consumers interested in bringing their own unique creations to life through i.materialise or who want to purchase a celebrated .MGX design.

RapidFit+ is part of the Materialise Group.

RapidFit,The ideal partner for you

- Production facilities in US and Asia

- Proven track record of installation’s in several countries

- Service technicians at your service

Global Responisbility

Materialise Offi ces

Materialise Distributors

RapidFit+ Offi ces

FastFacts

Strategic locations

Certifi ed partners

Over 10 years in Global Project Management

RapidFit HeadquartersTechnologielaan 153001 LeuvenBelgium

Phone: +32 16 39 62 85Email: rapidfi t@materialise.com

RapidFit Inc.35660 Beattie DrSterling Hts, MI 48312 U.S.A.

Phone: +1 586 275 0507Email: rapidfi t@materialise.com

Please visit our website:http://rapidfi t.com