Are you ready to Unleash and Exploit the full potential of Additive Engineering?

Design & Engineering Services

Our interdisciplinary engineering team works with you in a highly collaborative manner to find optimal solutions to very complex design challenges.  With a predefined methodology utilizing state-of-the-art software tools combined with experienced engineering, we accelerate idea generation and iterative design in order to achieve fully optimized physical structures.

Our design and engineering service model was developed with a clear understanding that each optimization or redesign project can present a unique set of requirements and employ varying levels of internal functionality. With that in mind we’ve deployed two simple collaborative approaches:

  1. “We do it with you” is a highly collaborative approach that works well for clients with initial concepts that would benefit from additional design considerations and input from our experienced engineering team. This approach also works well for projects with high complexity where additional interdisciplinary skills are required.
  2. “We do it for you” is an approach that is typically used for time sensitive projects where additional engineering support is needed. Provide us with a set of predefined specifications and our team will quickly develop design concepts for your approval.

Let our engineering team help you leapfrog traditional design exploration methods and provide an optimal solution that provides you with an end to end solution that is ready for AM manufacturing.

Are you ready to unleash and exploit the power and potential of additive manufacturing? Let’s talk.

Bionic Lightweight Design & Optimization

Today many challenges exist with traditional manufacturing technologies and methods to create lightweight structures. A primary benefit of Additive Manufacturing is the ability to significantly reduce mass and increase the performance and functionality of engineering structures. With Additive Manufacturing, it is now possible to custom design efficient, lightweight, bionic structures that bear the prescribed loads and perform the prescribed functions.

While additive manufacturing provides a newfound freedom of design, our team of engineers understand that coupled with enhanced design freedom are new design and manufacturing constraints. In order to exploit the use of non-intuitive bionic designs, our engineers take into account a new set of additive manufacturing design rules that are not associated with traditional manufacturing methods, such as the incorporation of support structures, limitations in wall thickness, and the incorporation of integrated features such as sensor mounts to ease mechanical validation for post-processing.

Optimization is more than topology optimization. Our team has a deep understanding of the additive manufacturing design lifecycle plus extensive materials knowledge to leverage capabilities of AM that maximize performance. With cutting-edge capabilities that extend beyond traditional methods were able to perform multi-physics simulations and optimizations to solve complex, multi-disciplinary design problems (mechanical, optical, thermal).

Re-think all that is possible with bionic design to exploit the new advantage of additive design that reveals a value-chain designed for repeatability and reliability.

(link to use cases SSTL and Sentinel 1, use verbiage from Altair)

Unoptimized traditional bracket
3D printed Antenna Bracket for a Sentinel-1-Satellite. Image: RUAG
Fully optimized bracket with increased performance and weight reduction of 41% Download Case Study

Paperless Design Industry 4.0

Conservation of our most precious resources is important to us, we employ an entirely paperless method and digital thread that incorporates 3D modeling, 3D pdf, and critical tolerance information that can seamlessly be integrated into downstream ERP systems or the manufacturing floor. Paperless design has been shown to reduce errors, accelerate design, enhance file sharing, and increase security.


An often overlooked benefit of Additive Manufacturing is that of component consolidation. Now, depending on the function and geometry of the overall system, multiple components can be fabricated as a single piece, eliminating interfaces wherever possible, significantly reducing the effort and cost associated with assembly and integration activities. Morf3D has a team of creative engineers to help redesign systems of components into single integrated components to avoid a locking into current design for assembly practices.

Additive Manufacturing also enables the incorporation of additional complex features such as cooling channels, fixations for harness or piping, part markings and ports for sensors into structural designs. Additionally, Additive Manufacturing allows the customization of a structural component design in ways that are extremely difficult, if not impossible, with subtractive methods and allows the ability to design for desired performance; whether it be frequency response, mass distribution or other desired characteristic.

Especially for low volume applications the high level of customization available with Additive Manufacturing makes this technology well suited for custom-fitting products. If you have a particular idea you would like to realize, allow Morf3D’s engineers to work with you to help bring your idea to tangible fruition and to exploit the full benefits of Additive Manufacturing.

Reverse Engineering

Morf3D has access to state-of-the-art precision scanning instruments in order to reverse engineer an existing part or structure.  Supplied with an original part, Morf3D’s team of engineers will reverse engineer it, provide CAD and STL files and produce either exact replicas, or work with the customer to optimize the original design for weight reduction, part consolidation, feature incorporation, or other customization.