case study

Protofusion 3D Expands Manufacturing Capabilities with Formlabs 3D Printing

As Protofusion expanded its 3D printing service bureau capabilities, it sought advanced additive manufacturing solutions that could support a wider range of customer applications with greater speed, quality, and scalability. Phillips Additive implemented the complete Formlabs ecosystem, SLA solutions, and a broad portfolio of engineering and medical-grade materials. This enabled Protofusion to deliver high-precision prototypes, functional parts, and medical components with faster turnaround times, superior surface quality, and enhanced application versatility across industries.

ADVANCED FRONT AXLE MACHINING ON HAAS VF-4 BOOSTS PRECISION & PRODUCTIVITY

An automotive manufacturer needed to machine three front axle variants on a single Haas VF-4. Challenges included height differences and tooling weight exceeding the machine’s ATC limits. Phillips Machine Tools developed a smart hydraulic fixture with color-coded, interchangeable components for fast, error-free setups. A tool parking station was added to handle heavier tools, bypassing ATC limitations. Poka-yoke mechanisms and PLC automation ensured accurate clamping and program selection. The result: clamping time reduced from 3–4 minutes to 10 seconds, improving precision, efficiency, and production consistency.

Turning a Tooling Problem into an Additive Breakthrough

A recurring tooling challenge with metal grippers on the PCM 220 machining center led to frequent breakage, high costs, and long lead times, impacting shop-floor productivity and uptime.

Phillips Additive addressed this by redesigning the grippers using Onyx composite and Markforged 3D printing (Mark Two) , enabling rapid local production, lightweight yet robust tooling, and easy design iterations. The solution delivered 70% faster turnaround, nearly 60% cost savings, zero breakage under high-frequency use, and seamless scalability across tooling applications, proving additive manufacturing as a practical, production-ready solution.

Full Thrust Ahead: Innovation for Maintenance of High Performance Industrial Gas Turbines

Swedish-based company, Siemens Industrial Turbomachinery AB (SIT), manufactures gas turbines for power generation in industrial and oil & gas applications. The performance spectrum of these Siemens industrial turbines ranges between 15 and 60 MW. Besides construction, the Siemens subsidiary also provides long-term service and maintenance for these engineering masterpieces. In an effort to help reduce maintenance costs, Siemens is currently working with the development and implementation of Additive Manufacturing technology, utilising EOS technology and equipment.

Improved Quality of Life Thanks to Cranial Implants Produced with Additive Manufacturing

Cranial implants need to meet the most stringent of criteria, with a large number of factors coming into play. This was the case with a patient in Argentina who required a particularly large implant after stroke-related surgery. The project called for a level of design for all relevant factors that was as close to perfect as one can imagine: from the highest degree of precision and compatibility to the integration of biological functions. The 3D-printing service provider Alphaform AG relied on EOS technology for the realization of this successful cranial implant which was developed by partner firm Novax DMA

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

Surgery on the human spine is one of the most exacting, delicate procedures in the operating room. While the skill of the doctor is of paramount importance to a good outcome, the precision and reliability of the instruments they use are also critical. As minimally invasive surgery (MIS) becomes one of the fastest-growing areas in spine treatment, orthopaedic surgeons are demanding increasingly sophisticated tools. These must be sized for greater access and control through smaller incisions, made strong enough to cut through cartilage and bone, and built from materials that are biocompatible.

Bespoke Medical Devices for Craniomaxillofacial Surgery

Additive manufacturing is revolutionizing the medical industry by allowing bespoke medical solution provider MAXONIQ to design and manufacture custom medical devices that are both efficient and cost-effective for the patient.

Czech Tool Manufacturer Relies on Additive Manufacturing for Complex Customer Projects

The quality of plastic vehicle components has increased greatly over the last years: complexity, high fitting accuracy, visual appeal and surface feel all meet the constant demand for premium quality – even in many of the high-priced models. Manufacturers and suppliers are relying more and more on high-tech solutions. One of the sectors in which the Czech Republic based company Innomia a.s. is active, is the automotive sector. The company has become a big advocate of the benefits of Direct Metal Laser Sintering (DMLS). Its portfolio spans prototype construction, the manufacture of inserts for injection molds and casting tools, tool repair and more. With the help of EOS technology, the DMLS professionals have supported the automotive supplier Magna in optimizing the production process for injection molded plastic parts. This involved a revision of the cooling process. The case concerns the manufacture of the armrest situated between the front seats.

Bronchial Gripper with Functional Base Plate Made Lightweight and Durable with EOS Technology

The hand is one of the defining milestones oder characteristics of human evolution: with its thumb opposing the other fingers, the human hand is an ideal tool for gripping, exploring, and working. As such, it is the key to cultural activity and technical progress. Industry often exploits this ingenious principle: one of the processes for which machines are used is the automated gripping of almost any desired part for transporting to the next operational step

Mass Production of Medical Nasal Swabs With 3D printing in Australia Ends Reliance on Overseas Supply

The COVID-19 pandemic has put companies’ global supply chains to the test in unprecedented ways. Many companies faced an initial supply shock when their global suppliers were disrupted due to limitations in travel and controlled trade for key medical necessities. Governments, businesses and individual consumers suddenly struggled to procure key medical products and materials, and were forced to confront the fragility of their global supply chain

Spinal Fusion Surgery Using SLS Printing Technology Saves Time and Improves Outcomes

Spinal surgery is a complicated procedure requiring an extensive and costly support network. Anatomics’ SpineBox™ method of pre-planning surgery and of manufacturing customized devices has the potential to realize significant time and cost benefits for the healthcare system. The streamlined procedure and solution not only improve the patient outcomes, they also reduce the risk of infection, as well as the strain on central sterile services departments (CSSD).

FHC Switches to EOS Technology for Manufacturing of Stereotactic Platforms for Neurosurgery

Brain surgery requires devices and instrumentation that are manufactured to the highest levels of precision. Deep Brain Stimulation (DBS), which treats acute symptoms of various diseases, targets areas of the brain that are measured in millimetres. Yet every person’s brain geometry is unique. FHC—a worldwide leader in innovative neuroscience products for more than 40 years—collaborated with a leading neurosurgeon to transform traditional stereotaxy using a 3D-modelling process based on each patient’s anatomical coordinates. The first application of this new STarFix technology is the award-winning, patient-matched, frameless microTargeting™ Platform, which offers greater patient comfort, increased accuracy and time savings in the operating room (OR). Using the FORMIGA P 100 to laser sinter the Platform, FHC achieves precision results at reduced costs within record delivery times.

A350 XWB cable routing – from design to component in two weeks

The moment when a completely new commercial aircraft takes to the skies for the first time is always special – and this was especially true of the Airbus A350 XWB. As a child of the new millennium, it was clear from the very beginning that development work would focus on innovative materials and production processes – the goal was no less than to build the world’s most efficient aircraft. As a technology of the future, additive manufacturing was another possibility that needed to be considered during development. As part of a pilot project, experts from Sogeti High Tech succeeded in developing a cable mount on the front spar of the vertical stabilizer for the passenger aircraft in record time, taking only two weeks from the initial sketch to the finished part. EOS technology and expertise was a pivotal aspect of this development process.

Help Is Fast at Hand Thanks to Additive Manufacturing: Alphaform Produces a Hip Replacement Designed by Instrumentaria

For anyone affected by it, a cancer diagnosis always comes as a shock: In the case of a boy from Croatia this was particularly true as an aggressive form of bone cancer had destroyed the teenager‘s hip. The only option for the doctors treating him was a complete reconstruction of the hip bone. Once again, the 3D printing experts at Alphaform, a company with extensive experience in the medical sector, placed its trust in EOS‘ technology to successfully produce the implant.

case study

Protofusion 3D Expands Manufacturing Capabilities with Formlabs 3D Printing

ADVANCED FRONT AXLE MACHINING ON HAAS VF-4 BOOSTS PRECISION & PRODUCTIVITY

Turning a Tooling Problem into an Additive Breakthrough

Full Thrust Ahead: Innovation for Maintenance of High Performance Industrial Gas Turbines

Improved Quality of Life Thanks to Cranial Implants Produced with Additive Manufacturing

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

Bespoke Medical Devices for Craniomaxillofacial Surgery

Czech Tool Manufacturer Relies on Additive Manufacturing for Complex Customer Projects

Bronchial Gripper with Functional Base Plate Made Lightweight and Durable with EOS Technology

Mass Production of Medical Nasal Swabs With 3D printing in Australia Ends Reliance on Overseas Supply

Spinal Fusion Surgery Using SLS Printing Technology Saves Time and Improves Outcomes

FHC Switches to EOS Technology for Manufacturing of Stereotactic Platforms for Neurosurgery

A350 XWB cable routing – from design to component in two weeks

Help Is Fast at Hand Thanks to Additive Manufacturing: Alphaform Produces a Hip Replacement Designed by Instrumentaria

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