SolidWorks for Engineers: Optimization, Simulation, and 3D Printing with Markforged

SolidWorks in Action: How Markforged Optimized Designs and Accelerated Development

Weight optimization, creating complex mechanical assemblies, load analysis, preparing models for 3D printing, rapid prototyping — for engineers, these tasks are part of the daily routine. But when you need to simultaneously reduce development time, minimize physical testing, and maintain structural strength, a comprehensive tool is essential.

Markforged, known for its composite 3D printers, faced these challenges while designing equipment and demonstration models for clients. SolidWorks played a key role in solving these tasks.

Engineering Challenge: Lightweighting, Complex Assemblies, and Manufacturing Requirements

Markforged works with designs where it is critical to combine high strength, low weight, and the ability to print quality composites. This imposes several requirements:

• optimize part shapes according to loads,
• prepare models to print flawlessly on composite printers,
• reduce the number of metal components,
• quickly and iteratively modify designs without reworking the entire assembly,
• identify weak points in the design before the prototype,
• shorten the time required for interaction between mechanical engineers and the production team.

Traditional tools could not simultaneously model, optimize, and prepare parts for composite printing. Engineers needed a comprehensive CAD and simulation suite that enabled rapid changes while maintaining precision.

SolidWorks as the Solution

1. Shape Optimization (Topology Study)
SolidWorks enabled Markforged to identify areas of excess material and areas critical for strength. Topology optimization allowed the team to create lighter parts with the same stiffness, adapting shapes for composite reinforcement.

2. Load Analysis (Simulation / FEA)
Using Finite Element Analysis (FEA), engineers could predict how designs would behave under real-world loads. This reduced physical testing and accelerated the prototyping cycle.

3. Modeling Complex Mechanical Assemblies
Many Markforged solutions include moving components — hinges, kinematic connections, and mechanical constraints. SolidWorks enabled precise tracking of component motion, detection of interferences, and design optimization without manual recalculation.

4. Preparing Models for Composite 3D Printing
With surface tools, controlled fillets, STL export, and precise geometry management, SolidWorks ensured smooth integration of models with Markforged printers.

5. Speed of Iterations and R&D
SolidWorks enabled the team to iterate much faster — modify the model, rerun simulations, and immediately prepare an updated version for printing.

“SolidWorks allowed us to quickly create accurate models and test them under load before printing. Without it, we would spend much more time on errors and rework. Simulation accelerated our development process by 45%.” — Markforged team.

SolidWorks Enables

• reducing design weight without sacrificing strength — critical for mobile platforms,
• replacing metal with composites where economically and technologically advantageous,
• rapidly creating prototypes for field testing,
• virtually testing part strength, saving time and resources,
• preparing models for different manufacturing types — from traditional milling to composite or metal 3D printing.

In an environment where speed of innovation determines competitiveness, SolidWorks helps companies operate at global engineering standards.

Softprom is a SolidWorks reseller from Dassault Systèmes in the region. We provide consultations, supply licenses, and help select the optimal solution for your tasks. Have questions? Submit a consultation request, and we will assist you.