Unlimital and BCT choose NX: end-to-end process chain for metal 3D printing

The Central Swiss company Unlimital AG is expanding its metal 3D printing offering with an integrated software environment based on Siemens NX. The goal is an end-to-end process chain from the CAD model through print preparation and topology optimization to subtractive post-processing.

“Supporting our customers in Design for Additive Manufacturing (DfAM) is very important,” says Jonas Hirzel, “because knowledge about the possibilities and requirements of metal 3D printing is relatively limited in many companies, and optimization potential often goes untapped. It starts with the placement of support structures, which we position—where possible—in places that we have to machine anyway. That way we minimize rework.”

“Lightweight design is not only in demand in areas such as motorsport or aviation,” Hirzel explains, “but also, for example, in automation. The lighter grippers and robot arms are, the more dynamically they can be controlled. Most CAD systems use the STL format to transfer to 3D print preparation. But that means if changes are made, you have to start completely from scratch, and the hours invested in developing supports are lost. That makes the process inefficient, especially for us as a service provider.”

The trigger for the switch was the STL-based handoff in the previously used system. Changes to the part required completely recreating supports and slicing parameters, which lengthened manufacturing loops. NX integrates these steps natively: support geometry, part orientation, overhang analysis, and slicing remain associatively linked to the solid model.

“I regularly skim the local business association’s member list for interesting companies,” says Martin Anliker, Managing Director at BCT. “Unlimital immediately stood out among the other businesses. I really enjoy working with high-tech startups because you can make a lot happen and be successful together.”

“For us, exactly the right functions were included,” Hirzel recalls. “For example, NX offers very mature preparation and simulation functions for 3D printing, as well as topology optimization and CAM.”

The implementation was carried out together with BCT Technology. Managing Director Martin Anliker emphasizes the usage-based license configuration with NX Tokens, which avoids over-licensing. During the evaluation, actual simultaneous module needs were measured and the package was then fine-tuned accordingly.

“And if something is changed on the actual part, the geometry changes in all modules without the preliminary work being in vain,” explains Hirzel. “That’s exactly the efficiency we need as a service provider.”

Anliker reports from the evaluation phase: “In contrast to the previous system, which provides startups with the complete product range free of charge for a period, Siemens offers a discount—so the system still costs money in the end. We therefore first analyzed which modules Unlimital really needed and then provided several test licenses. During live operation, we were able to observe how many tokens—that corresponds to floating licenses—of all modules were actually needed simultaneously and communicate the real demand. In this way we prevented over-licensing, and our customer has the optimal setup for the lowest possible financial outlay—which is an important topic for startups. We’re an ideal team to drive DfAM further into the market. Unlimital with its methodological know-how and BCT with our knowledge of NX and its functions can make companies fit for metal 3D printing quickly and efficiently.”

Since its founding in 2021, Unlimital has been supplying prototypes and series components for motorsport, aerospace, and medical technology as well as mechanical engineering. Lightweight construction and function-integrated structures are the focus, for example for grippers and robotics components. According to Hirzel, recurring savings of 20 to 30 percent in mass and material are achieved. The partners see the combination of DfAM methodology and NX know-how as a scalable approach to integrating metal AM into existing production workflows and keeping qualification efforts manageable.

“We recently managed to squeeze out another 20 to 30 percent on a customer part that had already been designed for additive manufacturing. For a competitive electric car, we were able to halve the weight of a part that was intended for CNC manufacturing. That’s a big win for performance applications like these. You don’t achieve such percentages only now and then, but regularly.

Service only makes sense if you can do things faster or better than the client. In NX, we were able to build a seamless process chain from the model through 3D printing to the finished, machined component. BCT helped us a lot with this and implemented an environment optimally tailored to our requirements. We will certainly continue to work well together and anchor additive manufacturing in the day-to-day operations of many companies,” Hirzel concludes.