CREDIT: MATERIALISE
Materialise, developer of additive manufacturing (AM) software and services, unveiled the 2025 Magics release alongside strategic partnerships with Raplas and One Click Metal. The announcements address key challenges in AM design limitations, part costs, and manufacturing speed to advance the use of AM in industries like aerospace, healthcare, and automotive. The company reports that the combined solutions of the new Magics release with nTop implicit geometries overcome traditional AM design challenges by reducing build preparation time from days to seconds while maintaining design precision. This new capability in Magics, combined with Materialise’s next generation of Build Processors, enables the printability of complex parts that could not be printed before.
“As additive manufacturing transitions from a niche technology to a cornerstone of modern manufacturing, the need for intelligent, integrated software is more critical than ever,” says Udo Eberlein, vice president of software at Materialise. “We are listening closely to the demands of the market and evolving our software portfolio into an integrated range of solutions that work together with other manufacturing tools. By addressing challenges such as cost, scalability, and precision, we are laying the foundation for seamless workflows that connect additive manufacturing to broader production ecosystems.”
Unveiling the 2025 Magics release: breaking design barriers and optimizing costs
The new release delivers tangible solutions for polymer and metal 3D printing challenges by allowing implicit modeling capabilities, intelligent support generation tools, and seamless workflow integration.
nTop implicit geometries integration
Magics introduces seamless processing of nTop implicit geometries without the need for mesh conversion, drastically reducing preparation time for complex parts. Paired with the advanced slicing capabilities of Materialise’s next-generation Build Processors, it enables the design and production of parts that could not be printed before due to substantial data and memory requirements.
BREP import and processing
The new release's extended BREP processing capability enables users to work with native CAD geometry throughout Magics, ensuring higher part quality, faster performance, and a reduced need for manual fixes. Ideal for CNC workflows as well as SLS, MJF, and Metal LPBF users, it streamlines operations by supporting advanced functionalities such as measurements, wall thickness analysis, nesting, and STEP file export for seamless integration into CAM or CAD software.
Optimizing part costs
With post-printing accounting for 40% to 60% of total costs, the latest Magics brings further optimizations for build preparation workflows and support generation, reducing material use and post-processing requirements while maintaining high-quality output. Key features include:
- Replace Part & Transfer Support: Designed for series production and prototyping, it facilitates design interactions more easily for NPI and product improvements by seamlessly transferring support when using the Replace Part function, reducing repetitive work, human error, and lead times.
- Self-Supporting Shell & Honeycomb: Minimizes supports in complex areas with self-supporting volumes, simplifying removal and reducing post-processing efforts. Designed for LPBF, it also benefits other technologies, enabling higher-quality parts with fewer supports.
Magics' new release also includes several functional updates to simplify the user experience and significant rendering and memory usage optimizations for more efficient, responsive workflows. It delivers up to 40% less video memory usage for marked mesh parts and accelerated operations like Extrude (70%) and Perforator (50%). The new Magics release will be commercially available in May 2025 and is being showcased at Rapid+TCT.
Accelerating AM: pushing print speed and performance to the next level
Materialise announces two next-generation Build Processors through partnerships with Raplas and One Click Metal, advancing AM capabilities across large and mid-market AM production.
Focusing on AM scalability, Raplas and Materialise announce the Raplas next-generation Build Processor for series production in resin-based additive manufacturing. With more than 30 years of expertise in SLA equipment and resin material production, Raplas has established itself as a trusted player in the industry by delivering customer-focused solutions.
“By combining Raplas' tailor-made SLA 3D printing technology with Materialise's advanced Build Processor, we are addressing inefficiencies of legacy systems. This partnership has already demonstrated remarkable results, including a 30-40% increase in printing speed, enhanced part quality, and minimum post-processing requirements,” says Richard Wooldridge, CEO of Raplas. “Together, we are empowering production environments for faster, more accurate end-use parts, advancing applications in the medical, automotive, and aerospace sectors, and technologies such as investment casting.”
Earlier in March, Materialise announced a Build Processor integration with One Click Metal to support the rapid growth of the mid-market 3D printing sector. This collaboration addresses the increasing demand for solutions that balance affordability with performance, providing flexible and scalable options for both startups and established manufacturing facilities. By integrating Materialise’s Build Processor into One Click Metal’s ecosystem, users gain enhanced control over their production processes, streamlining operations while ensuring consistent, high-quality results.
“Materialise’s strategy is to enable the next generation of additive manufacturing by combining advanced software with diverse hardware platforms. Collaborations with Raplas and One Click Metal and the launch of the 2025 Magics release reflect our commitment to supporting the full spectrum of AM production. These solutions empower customers to save time, reduce risks, and lower costs, supporting successful AM builds from start to finish,” states Bryan Crutchfield, vice president and general manager of Materialise North America.