Measuring Excellence: On the Floor at Hexagon Dwell in Fabulous Las Vegas – 3DPrint.com

July 4, 2025

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Two weeks in the past, I drove roughly 66 miles from Dayton, Ohio to the Cincinnati airport in northern Kentucky. I then flew about 595 miles to Minneapolis, Minnesota, switched planes, and flew one other roughly 1,296 miles to the desert of Las Vegas. An Uber picked me up at Harry Reid Worldwide Airport and drove me one other 4.8 miles to the gorgeous and blissfully air conditioned Fontainebleu Las Vegas, with its 150,000-square-foot on line casino that I didn’t enter a single time besides on my strategy to dinner or the periods at Hexagon Dwell.

“To measure is to know.”

That’s what Ola Rollén, CEO of Greenbridge and the Chairman of the Board for Hexagon AB, mentioned in his opening keynote. From cubits and furlongs to toes, miles, and kilometers, measurement applied sciences are integral to our lifestyle.

Hexagon, the worldwide chief in measurement applied sciences, is celebrating its twenty fifth anniversary this 12 months. Rollén gave a quick overview of the corporate’s historical past, from sensor growth in 2000 to the “watershed second” in 2010 of “bridging the bodily world with the digital” by way of using digital twins.

“Use your capabilities within the software program world to simulate and make higher earlier than you create the bodily product,” he defined.

He shared the instance of Dr. Andrew Tallon, who was given permission in 2015 to make use of laser scanners to seize the intricate particulars of Notre-Dame Cathedral. Nothing was executed with the info till 2019, when the historic Gothic constructing caught on fireplace. Dr. Tallon had sadly handed away by this level, however his widow shared his scans with the undertaking group, so they may higher reconstruct the cathedral by way of using a digital twin.

Hexagon Bulletins

Rollén shared two large Hexagon bulletins throughout his keynote, beginning with a choice the Board of Administrators made to spin off two of its older acquisitions—ETQ and Bricsys—together with the corporate’s Asset Lifecycle Intelligence (ALI) and Security, Infrastructure and Geospatial (SIG) divisions, right into a separate firm. He welcomed Mattias Stenberg, the president of the ALI division, to the stage, and introduced that he could be the CEO of the ensuing industrial software program and SaaS enterprise, Octave, launching in early 2026.

“We’re taking it up an octave!” Stenberg advised us.

He defined that Octave could have “the pliability to speed up innovation and set up a robust platform for future M&A.” Stenberg additionally mentioned that with 7,500 workers and €1.5 billion in income proper off the bat, it’s a unicorn firm from the primary day. Octave can be centered on designing, constructing, working, and defending the world’s most mission-critical belongings, like knowledge facilities, electrical era and grid infrastructure, essential transport hubs and corridors, and extra.

Rollén returned and advised the gathered crowd that the long run we’re headed for is true autonomy. He requested attendees to boost their palms if that they had two or extra youngsters, and congratulated them on serving to to make sure our future, explaining that persons are having fewer youngsters, which can ultimately “trigger a world financial disaster.” As somebody who’s childless by alternative, I used to be slightly bowled over (and mildly offended) by this, however I understood his level when he welcomed Arnaud Robert, President of Hexagon Robotics, to the stage for the second large announcement: AEON.

The humanoid robotic, which zipped out onstage a couple of minutes later and waved to everybody, combines Hexagon’s sensor suite with superior locomotion, spatial intelligence, and AI-driven mission management to handle labor shortages and meet real-world buyer wants. Robert mentioned that robots have to be multi-purpose and adaptable, in a position to kind small items in the future, like nuts and bolts, after which bigger, bulkier elements the following.

A better take a look at AEON on the present ground

AEON, which is powered by NVIDIA applied sciences, is supposed to enrich the human workforce, in a position to full tedious, even harmful, duties alongside individuals. The Robotics division is partnering with Schaeffler and Pilatus to pilot the robotic throughout manipulation, actuality seize, machine tending, and half inspection use circumstances.

Wyve’s 3D Printed Surfboards

Whereas Hexagon is just not a 3D printing firm, its many options, like Geomagic, are sometimes utilized in tandem with 3D printing. There have been just a few displays on the occasion that showcased these purposes, beginning with one about French firm Wyve, which makes bio-based surfboards. By using FFF 3D printing, the surfboards last more, are extra light-weight, and cheaper.

“We’d like to regulate the skeleton of each surfboard, that’s what we’re engaged on,” defined Wyve surf scientist Paul-Élie Charles.

Charles was joined by Benjamin Ostré, Affiliate Professor on the College of Toulon’s Mapiem Laboratoire (Polymer Supplies Interfaces Marine Setting Laboratory). They mentioned that Wyve’s 3D printed surfboards, which measure about 2 meters lengthy, are extra sturdy than conventional surfboards as a result of they’re made out of robust plastic, reasonably than fiberglass and epoxy laminate.

Utilizing Hexagon’s laser scanning capabilities, the researchers captured knowledge from the physique of a standard surfboard and created a digital twin to reverse engineer it. Charles and Ostré defined the significance of putting simply the correct quantity of fabric for the Wyve board precisely the place it’s wanted; as we all know, 3D printing is ideal for this. A number of of Hexagon’s software program options had been additionally used throughout the course of, comparable to Digimat and ESPRIT EDGE. In the end, the core of every Wyve surfboard is printed with variable geometry, with the construction’s densities and thicknesses optimized, as the corporate explains on its web site, “in relation to the browsing model proposed by the board’s form.” The core is printed in a single piece, and it takes roughly 40 hours of printing to manufacture a board that’s 5′-6′ lengthy, whereas a 7′-8′ board is extra like 60 print hours.

A number of PhD college students with the Mapiem Laboratory labored with Wyve on the 3D printed surfboards, and two scientific papers had been printed concerning the work as effectively.

“We’re looking for the proper mechanical traits of the board so each surfer, all over the place on the planet, can use it, with supplies that received’t have an effect on the setting,” Charles mentioned.

3D Printed Scapula Reconstruction

Medical AM purposes are one among my favourite issues to jot down about, so I used to be excited to attend a presentation by Hexagon’s Mathieu Perennou, World Technique and Enterprise Improvement Director, Additive Manufacturing, and Lee Goodwin, Principal Software Engineer at PTC. They shared a case labored on by Dr. Solomon Dadia with Tel Aviv Sourasky Medical Middle and Dr. Ronen Ben Horin, PTC’s VP of Know-how, concerning a 16-year-old lady with Ewing sarcoma, a really uncommon most cancers that causes bone degeneration. The affected person was experiencing important ache and swelling in her proper shoulder, and an MRI confirmed important bone loss.

Goodwin defined that the scapula, which is related to almost 20 totally different muscle tissue, is “a really essential bone,” making an individual’s arm work “from a macro standpoint.” So a personalised implant was essential for the affected person to take care of a working arm. There have been a number of vital design concerns to keep in mind for the 3D printed implant, together with:

preserving the affected person’s authentic anatomical form, quantity, and kinematics (the way it strikes)
minimizing weight whereas optimizing mechanical properties
implementing a complicated lattice construction to facilitate connective tissue and muscle regeneration
utilizing superior mechanical simulations to confirm the implant’s load-bearing capability

They selected titanium for the implant, which is 9 instances stronger, 4 instances stiffer, and thrice extra dense than human bone. This materials was additionally chosen as a result of a lot of the burden could be faraway from the ultimate implant. In an earlier dialog, Perennou had defined to me that if an implant is simply too robust, the encircling bone will grow to be weaker and degenerate, as a result of it basically thinks that the implant can tackle all the stress. So a weaker implant could be higher.

Utilizing MRI scanning, the group captured the essential form of the wholesome scapula, after which did a mirror picture. The implant was designed utilizing PTC Creo CAD software program. Goodwin defined {that a} lattice construction was used so bones would connect to the implant. Evaluation capabilities within the software program had been used to seek out stresses and deformations within the implant to make sure that it was versatile in addition to robust. The Creo design was then introduced over to Hexagon’s AM STUDIO construct preparation software program to find out the perfect printing place and generate a slice file. Simufact Additive software program, which Perennou referred to as a “digital printer,” was used to calculate the distortions “so you possibly can compensate and mitigate any manufacturing points forward of time.”

The implant was printed on an EOS M290, and after post-processing, Hexagon’s VGStudio Max was used to scan it for qualification and inspection functions. Lastly, the surgeon signed off on the 3D printed implant, and the younger affected person as soon as once more had a working arm; Goodwin mentioned she is at the moment present process rehabilitation.

The entire course of, from scanning and design to 3D printing and inspection, took simply 4 days. If that isn’t a ringing endorsement for 3D printing within the medical sector, I don’t know what’s!

Boeing Leveraging an AM Digital Thread

Nick Mulé, Director of Additive Manufacturing for Boeing, shared how the aerospace big achieves high quality at scale by leveraging an AM digital thread.

“Additive has been flying the Boeing platform for over 20 years,” he advised us.

Since 2016, Boeing has been 3D printing for essential purposes, like satellites, command horn antenna, and engine mounts, to call just a few.

Mulé’s Boeing AM group (BAM) is on the digital integration aspect of issues, with a variety of portfolios, together with construct file growth, modeling and simulation for additive, machine studying, and digital twins. Whereas plenty of work is being executed within the polymer house for purposes like tooling, Boeing’s heaviest focus is on steel powder mattress fusion and DED. He defined that in the case of utilizing AM, Boeing is on the lookout for worth add: will the know-how improve efficiency, enhance high quality, allow producibility and scale back meeting? The corporate has just lately seen plenty of AM worth add within the satellite tv for pc house, comparable to warmth exchangers and smallsats.

“So, why is digital transformation vital?” he requested us.

You consolidate experience in an organization, so you possibly can have tight management over your merchandise. However, as we work to scale, Mulé mentioned we “must be aware of additive,” as a result of whereas it may be very helpful, there are plenty of variables that must be optimized and managed so the elements come out precisely proper. These embrace uncooked materials variables (chemical composition, traceability, certified suppliers), design and modeling variables (DfAM and construct file era), manufacturing course of variables (strong parameters in place, high quality management, machine qualification), and extra.

“When you lock these down to satisfy aerospace necessities, you don’t need the variables to alter.”

So how can we method the digital thread? Mulé defined that it’s doable to have terabytes value of information with none context, which could be onerous later once you’re attempting to take motion on one thing. So the purpose is to transition so the info is saved on the 3D printer, with particulars like geometry included so as to add context and perception. As Mulé mentioned, “your fashions are solely pretty much as good as your knowledge.” So once you’re working to develop a brand new additive course of, you possibly can take a look at the scan-level knowledge saved within the printer, and mix it with evaluation datasets to determine extra methods to optimize AM.

There are various traits on the ecosystem stage that following an AM digital thread may assist with, comparable to integrating design with simulation and scan path era, utilizing a thermal mannequin for scan-level temperature gradient prediction, validating course of monitoring for DfAM suggestions to optimize course of management, and in-process machining for higher floor and dimensional management.

Americas State of Manufacturing 2025 Report

Throughout Hexagon Dwell, the corporate shared the outcomes of “The Americas State of Manufacturing 2025 Report.” Carried out by Dynata and commissioned by Hexagon, the report surveyed 500 professionals from the manufacturing trade, and never simply CEOs, however entry-level workers and senior managers as effectively. I appreciated that Hexagon held a particular session only for the assembled journalists to share a number of the preliminary knowledge.

“Manufacturing has a notion drawback when talking with Gen Z,” defined Paul Rogers, President of Americas and Asia Pacific for Hexagon Manufacturing Intelligence. “They count on digital, clear, high-tech environments, with automation, and never darkish, soiled factories.”

Rogers additionally famous that it’s a giant funding to coach and re-educate the prevailing workforce for a digital, automated setting, and could be onerous to justify ROI of those efforts. The primary statistic he shared was very reflective of this, as solely 8% of these surveyed mentioned that sufficient is being executed to reskill the workforce.

One other key discovering was a considerably disturbing disconnect between management and their workers. 60% of respondents consider they’re doing sufficient to make the manufacturing trade extra interesting to new expertise, however whereas 86% of executives consider these efforts have elevated curiosity in manufacturing, solely 59% of entry-level staff agreed.

Rogers mentioned that by 2033, there can be 3.8 million out there manufacturing jobs, however just one.9 million of these positions can be crammed, which is a reasonably large hole. A few of this is because of some notion challenges about manufacturing jobs, comparable to restricted profession progress, outdated or unsafe workplaces, low-skill or repetitive work, and a male-dominated tradition. Moreover, 56% of producing professionals are involved about tariffs and coverage adjustments, 45% are frightened about provide chain disruptions, and 44% suppose that inflation can be an issue. These points may additionally influence the choices of people that could be thinking about working within the manufacturing trade.

“This guides our portfolio,” Rogers mentioned. “How can we assist producers scale back their reliance on workers when there aren’t sufficient?”

One instance is the newly launched humanoid robotic AEON, however lots of Hexagon’s different applied sciences can even assist with this. You could possibly see many examples on the present ground, which was known as The Zone. There have been frequent periods showcasing the robotic at work, and I additionally acquired a hands-on take a look at the brand new Hexagon Maestro digital CMM system, in addition to Hexagon TeleOp, a distant management know-how designed for protected operation of heavy equipment and tools.

: Hexagon Maestro

: AEON

: Hexagon TeleOp

Rogers shared one other troubling end result: 72% of respondents say that outdated know-how is at the moment stopping them from attracting and retaining staff, which is a fairly essential barrier. However, 96% consider that their operations can be positively reworked by know-how within the subsequent 5 years, whether or not by way of simple integrations or time and value financial savings. Plus, as beforehand talked about, loads of Hexagon’s options might help democratize manufacturing. The Leica ATS800 tracker helps remove bottlenecks related to giant elements, whereas ESPRIT EDGE software program makes use of AI-driven programming to optimize toolpaths for sophisticated machines. The corporate’s quick, modular suite of robotic inspection cells, PRESTO High quality Stations, makes automated high quality inspection accessible, and the Nexus platform makes use of cloud know-how to attach manufacturing and engineering methods.

“Automation is not a menace to the manufacturing trade, however an expectation,” Rogers mentioned.

Last Recap

I actually loved my time at Hexagon Dwell! The occasion was run extremely easily, with only a few glitches; not less than none that I seen. There was a very good mixture of principal keynote displays and smaller, extra centered displays, and I discovered rather a lot about Hexagon and its large portfolio of options. Keep tuned for extra information from Hexagon Dwell, and till then, get pleasure from some extra occasion photos beneath!