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Here at Mammoth4D we are dedicated in providing our clients with a full 3D print solution, from the initial design & consultation, through to the final print and build. Our experienced team offer a complete understanding of the endless 3D printing applications available on the market, ensuring you receive a custom solution that is specifically tailored to the needs of your project.

One of the many advantages of 3D printing is the ability to manufacture prototypes and low production runs in a timely and cost-effective manner. Through eliminating the high cost of injection moulding, this new method of producing objects allows companies to save valuable time with the ability for projects to be completed in days rather than months.

Through our offered services, we can assist in the creation and scanning of your 3D print files. We offer an extensive library of post processing finishes for each project, from sanding and polishing, to painting and airbrushing the final product.

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Mimaki Full Colour 3D

The Mimaki is our smaller, high-resolution colour 3D printer. Do not underestimate this printer...

It may be smaller, but its ability to print photorealistic objects is unlike any other printer in the world.

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The Mammoth is a large-format 3D printer that is like no other in Australia. With an internal printing space of 145w x 180h x 111d and a print speed of up to 30cm/second, it sets the standard in 3D printing, as it is the biggest and faster 3D printer in the world.

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3D printing of a mammoth skeleton: project overview

Implementation stories

Author: Nikita Kudryashov

How to print a life size mammoth? | Large format 3D printing in action | Skeleton, scanning and "invisible" supports | Attention to detail from start to finish

The Royal Belgian Institute of Natural Sciences in Brussels (RBINS), founded in 1846, employs more than 250 research scientists. There are 38 million exhibits here, including from 1869year, the Lyra mammoth is the first skeleton of its kind put on public display in Western Europe.

Discovered, as the name implies, near the town of Lier in the province of Antwerp, the skeleton is still one of the few intact mammoth skeletons. The rare exhibit is extremely important for science, not to mention the fact that it attracts lovers of natural history from all over the world. Thus, there was a great chance to make a gift to the Lira city museum, timed to coincide with its re-opening. It is impossible to move the mammoth skeleton from Brussels, but it can be recreated!

The Lir preservation team, led by local Kiwanis volunteers, approached Materialize with an exciting idea: use 3D printing to create a life-size replica of the skeleton. In other words, use modern technology to return the prehistoric resident of Lear to his native land. After 320 bones were printed in 1260 hours, the Lyrian Mammoth 2. 0 was born.

"Bones" are covered with several layers of paint of various shades and a protective layer of varnish

How to print life size mammoth skeleton?

When you want to reproduce an exact copy of a mammoth, it becomes clear: size matters. Recreating more than 300 bones, some of which are more than 2 meters long (larger than a grown man!), is not an easy job. Given the fragility and risk of damage to genuine bones, the project was a unique challenge.

“When the skeleton arrived at the museum in 1869, the innovative technology was that the bones did not need to be drilled or otherwise broken to show the mammoth in full size,” says Royal Institute paleontologist Dr. Mitje Germonpré, who worked closely with Materialize on project. “Naturally, no one wanted to risk the natural integrity of the skeleton in this new endeavor.”

Similar creative thinking and technical solutions took place during the creation of the copy. Instead of using an external support structure like a genuine Lyran mammoth, the plan was to create the most inconspicuous internal support that would really bring the model to life.

Stereolithographic printers, which we called Mammoth, were first used in 2001. With a build chamber of 2100 x 700 x 800 mm, they are ideal for printing large objects in one session.

Gertjan Brinen, Project Manager

3D printing provides incredible design freedom and precision, so it was a natural choice for this technology. As Dr. Germontpre notes, “3D printing is increasingly proving to be an extremely useful tool for paleontology. For example, we can study fossils without damaging precious authentic specimens and work on the same fossil in a virtual environment with colleagues from all over the world.” But how do you print life-size bones?

Printing on a stereolithographic 3D printer

Large format 3D printing in action

The answer to this question was Materialize's stereolithographic 3D printers, which were managed by project manager Gertjan Brinen and a team of 19 people, including engineers, CAD and post-production specialists, as well as experts from the Institute, including Dr. Germontpre.

“Stereolithographic printers, which we called Mammoth (“mammoth”), were first used in 2001. With a build chamber of 2100 x 700 x 800mm, they are ideal for printing large objects in one session,” says Brynen. “At that time, we were thinking about solving such problems as printing prototypes of car dashboards, architectural models, large parts for industrial and production needs for individual orders. But the bones... It was a new challenge that we took on with pride and excitement.”

Materialize's Mammoth stereolithography printers deposit a 1/10 mm layer of UV-sensitive liquid photopolymer in one go, which is selectively laser-hardened to precisely match the required design specifications. To create special supports for the shape of the bones and laser sinter small bones (including mammoth vertebrae) and connection points, nine 3D printers must run for a month. But before printing could begin, the dimensional data had to be captured and optimized for 3D printing. “The launch date was only two months away,” Brynen adds, “and every step had to be carefully planned.”

The massive project brought together a team of 19 people, including engineers, finishers and artists, as well as a paleontologist

Skeleton, scanning and "invisible" supports

The external support structure of the original skeleton allowed the museum to detach and scan each bone individually in situ, passing the data to Materialize. Since the replicas accurately reproduced the original dimensions of the bones, each scan was cleaned and optimized for 3D printing using the Materialize Magics software, with each bone oriented along three axes for precise positioning. This allowed Dr. Germontpre and the Materialize engineers to perform a complete digital reconstruction and analysis of the skeleton.

“It was a defining moment in the project,” recalls Dr. Germontpre. “We could verify the match with the real skeleton using advanced scientific thinking and technology. Do not forget that the skeleton was mounted more than 150 years ago based on the anatomical knowledge of that time. For example, in the 19th century, scientists assumed that the tail of a mammoth was as long as that of an elephant, but after the discovery of the frozen remains of mammoths in Siberia, we know that in fact it was shorter. It was a great opportunity to virtually adapt the skeleton to the new knowledge of anatomy that we have today.”

After 3D scanning each of the 320 fossilized bones, Materialize engineers collaborated with a paleontologist to digitally reconstruct the skeleton.

The 3D printed reproduction also allowed the team to solve another problem with the authentic skeleton: “The Lyrian mammoth was missing several bones, including the left tusk,” Gertjan Brynen explains. “They have been replaced with sculpted wood crafts. Using the Materialize 3-matic software, we were able to make a more accurate copy by creating a mirror image of the right tusk. A broken upper jaw was also repaired. Overall, reconstructing the missing bones and correcting assembly errors meant that the new 3D-printed Lyra mammoth was even more scientifically accurate than the original, according to Dr. Germonpré.”

The digital phase of the project also included thinking of a new "seemingly invisible" mounting system that would allow the mammoth to appear free-standing. For Gertjan Brinen, this was a key moment. “Our subsidiary, RapidFit, has a lot of experience in using carbon fiber frames for automotive tooling. The context is completely different, but the task is the same: to create a relatively light, yet strong structure. RapidFit helped us design a custom modular carbon frame that resided predominantly inside the printed skeleton.

We also needed replicas of the bones to faithfully reproduce the originals and matched with internal carbon tubes that had to be mated with specially designed laser-sintered connectors to hold the complete skeleton. Our designers accomplished this by integrating the entry and exit points in such a way that they ended up perfectly aligned with the frame. The final structure, including the framework and the skeleton itself, weighed just under 300 kg.”

Attention to detail from start to finish

The total printing time for the Lyra mammoth skeleton was just over 52 days, with several 3D printers running at the same time, which was the only way to meet the tight deadlines. After printing each new batch of bones, a special Materialize team treated them with various paints, textures and varnishes so that the printed bones were as similar as possible to the real ones. Eventually, it was time for the new Lyrian mammoth to take on its final form.

Mammoth skeleton during assembly

“During the digital phase of the project, we took every care to ensure that the bones, frame, and printed polyamide connectors fit together perfectly to form the final mammoth skeleton. There was only one way to get it right,” Brynan recalls. “So our finishing team set about assembling the mammoth at our facility in Leuven. It was a magnificent sight!”

The result is an exact, anatomically correct copy. But it still had to be moved to a new location. Brynen continues: “In view of the need for transportation, we designed the skeleton from six assembly units: four legs, a spine and a head. For example, the vertebral section consisted of 30 separate parts connected by carbon tubes.” After the individual parts of the skeleton arrived at their destination in Lyra, the mammoth was reassembled - again in its native territory, which will now become its permanent habitat.

Brynen concludes: “In just seven weeks, we have managed to create a new piece of history that will bring great pleasure to new generations of visitors. This project leveraged all of our areas of expertise, from print optimization and design to manufacturing and finishing, everything that makes Materialize a unique player in the 3D printing space. And it was definitely a team effort: we couldn't have done it without the wonderful team of expert consultants and scientists who worked with us. Despite the fact that it was about preserving the past, the project was a perfect example of the futuristic application of 3D printing already today. Personally, I was very pleased to see how the client successfully implements a large-scale — literally — idea with us!”.

Material provided by Materialise. The original article is at the link.

Article published on 04.12.2018, updated on 07.02.2022

Largest SLA 3D Printing Project: Mammoth Skeleton Restoration

Largest SLA 3D Printing Project: Mammoth Skeleton Restoration

Materialize is currently running its largest SLA 9 project0083 3D Printing : A modern 3D reconstruction of the first mammoth skeleton.

The project will allow the Institute to restore the exhibition and present visitors with a 3D printed miracle. The original skeleton has been at the institute since 1869. It no longer represents the current scientific understanding of the Lear mammoth anatomy. For example, due to the fact that the tail in the original is much longer than the one we see now.

Creating a bone structure for a creature from the distant past is no easy feat. On the one hand, data may be missing, and modern fossils may not be as complete as needed for reference material.

The skeleton consists of 320 bones that have been scanned and digitally reconstructed using the Materialize Magics software.

Mammoth reconstruction presented a major challenge for Materialize engineers. Each bone was scanned in a museum in Brussels and then the skeleton was digitally reconstructed in close collaboration with Dr. Mie Germonpré, resident paleontologist at the Royal Belgian Institute of Natural Sciences, who worked on the materialization project to achieve the highest degree of anatomical accuracy.

In addition, each scan also needed to be cleaned and prepared for the 3D printer using the Materialize Magics software, as the scan does not create structural sound 3D shapes that are suitable for 3D printing of .

Mammoth Exhibit Restoration

Instead of using the original 19th century external mounting system, Materialize engineers also designed a more complex carbon internal mounting structure for the skeleton. While working in the digital phase, the materialized engineers had to think about how to fit the structure inside the bones and integrate the entry and exit holes in the bones for the carbon tubes. For the modular carbon structure, Materialize drew on the experience of its subsidiary RapidFit in automotive technology. The result is a strong and lightweight construction that weighs only 300 kg.

“The scale of the project is challenging, especially as we had to bring different experts together, including engineers, palaeontologists and finishers, and align our vision for the finished model, all the while meeting tight deadlines,” said Gertan Brienen, Project Manager the Materialize project.

“The original skeleton presents some inaccuracies that reflect knowledge from the original installation 150 years ago. One example is the length of its tail, which we now know is shorter than originally thought. The original mammoth skeleton is also missing several bones, including the left tusk. We scanned the correct tusk and recreated it in Materialize 3-matic to achieve a more accurate replica than the wooden tusk used to complete the original skeleton. The fractured upper jaw was also faithfully restored by mirroring part of the original bone structure. This means that The 3D printed mammoth will be more scientifically accurate than the original.”

The bones will be 3D printed on Materialize's nine Mammoth SLA 3D printers, which have been specially designed for projects requiring high printer capacity (220x70x80 printer slot size). It will take over a month to 3D print the mammoth as Materialize printers can only apply 1/10mm of resin at a time. The bones will then be 3D printed, painted with a combination of different varnishes, paints and textures to resemble the original skeleton.