<p id="isPasted">The Royal Netherlands Navy has a rich history and a modern edge. With a vast fleet of ships, helicopters, boats, and submarines, they are a global presence, often stationed far from home on challenging missions. Their commitment to excellence and innovation keeps them at the forefront of maritime defense.</p><h2>Spare part and logistical challenges</h2><p>The Royal Netherlands Navy faces the significant challenge of maintaining their fleet, wherever they are. Their assets often require spare parts, presenting a logistical dilemma. Carrying large quantities of unused spares consumes valuable space, adds weight, and incurs high costs. Transporting these spares, especially via helicopters, can take weeks and is extremely expensive, if it’s possible at all. Additionally, suppliers sometimes cease production of essential spares, complicating operations.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/gkNm7Sl7aew?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-gtm-yt-inspected-24="true" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><h2 id="isPasted">3D printing as a solution</h2><p>To tackle this major challenge, the Royal Netherlands Navy has adopted 3D printing. This allows them to produce spare parts locally and on-demand. Each ship is equipped with UltiMaker 3D printers and a variety of materials, enabling them to print a wide range of applications.</p><p>Parts are designed and tested at their headquarters in Den Helder. Once approved, they are added to a digital catalog. Crew members simply need to select and print the necessary parts directly on board. The Navy also prints optimized parts for better performance, which can be distributed digitally, and produced locally.</p><p>The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards. Cura is the most popular slicing software used to prepare 3D models for printing, while UltiMaker's Digital Factory platform enables users to manage and monitor their 3D printers and print jobs remotely, enhancing workflow efficiency. Even with large teams, Digital Factory prioritizes security and ensures that data remains protected throughout the process without compromising accessibility.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087595130-the-royal-netherlands-navy-fleet-of-printers.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p>The Royal Netherlands Navy uses a range of filaments, including ABS, PETG, and composite carbon fiber. For instance, PETG is selected for applications that require resistance to extreme temperature, wear, chemicals, and water and moisture absorption. In this instance, the Navy needed a material that would be resistant to saltwater. Using PETG, they 3D printed a new water filter to replace an old brass one</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087624501-1732087624501.png" class="fr-fic fr-dib"></p><p id="isPasted">Composite carbon fiber filaments are used when parts need to be both strong and lightweight, such as a landing boat antenna bracket printed by the Royal Netherlands Navy. Marine antennas are essential for communications and safety. These mounts ensure they are securely in place and allow for the safe lowering and raising of the antenna. Carbon fiber is especially valuable as it allows traditionally heavy parts to be printed with a light material, reducing weight on the carrier as well as the need to transport heavy items across the globe.</p><p>This variety of materials allows the Navy to create parts suitable for any environment or condition. Parts on ships primarily require strength and wear resistance, while parts for land or air troops often need to withstand extreme heat or cold. For example, brackets mounted on land vehicles must endure prolonged sun exposure. With the Royal Netherlands Navy's global presence, these parts must be prepared for a variety of demanding conditions.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1732087646194-the-royal-netherlands-navy-cura.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Thanks to Cura software's capabilities, UltiMaker 3D printers can seamlessly use both UltiMaker’s and third-party filaments, providing greater flexibility for users. Cura provides a streamlined experience with UltiMaker printers, offering optimized print profiles and faster printing, while maintaining compatibility with third-party products. UltiMaker is committed to regular security updates and providing new feature updates to its Cura users.</p><p>The Royal Netherlands Navy is a classic example where local manufacturing excels over traditional spare part solutions. Having printers on their ships prevents the need for large stocks of spares on the ships. Furthermore, many parts don't have to travel to remote locations, saving time and extremely high cost. These benefits also apply to many other industries. Factories can benefit from local part production, ensuring uptime of production processes, saving on industrial space and preventing parts to be flown in.</p>

The Royal Netherlands Navy uses UltiMaker's 3D printing software, Cura and Digital Factory, to meet strict operational requirements with secure and reliable production that aligns with IT security standards.

On-Demand Spare Parts: The Royal Netherlands Navy's 3D Printing Solution

<p data-pm-slice="1 1 []" id="isPasted">In manufacturing, the ability to quickly produce high-quality components on demand is critical. While metal 3D printing is often associated with producing unique, complex parts, its potential for serial production is frequently overlooked. This case study of the driver component for the <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">BOLDseries</a> by <a href="https://oneclickmetal.com" target="_blank" rel="noopener noreferrer">One Click Metal</a> demonstrates how metal additive manufacturing can effectively meet the challenge of producing components quickly and repeatedly, offering a viable alternative to traditional manufacturing methods that rely heavily on external suppliers.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731664133191-3.png" style="width: 508px;" class="fr-fic fr-dib"></p><p><strong>The Challenge: Quick and Frequent Production with Limited Supplier Reliance</strong></p><p>One Click Metal faced a pressing need to produce a large quantity of driver components for their BOLDseries metal 3D printer. The driver is a key part responsible for opening and closing the powder-filled cartridges, and it needed to be produced with precision and durability. Traditionally, these parts would be manufactured through CNC machining, which, while reliable, comes with significant drawbacks—especially when rapid production is required. Outsourcing to suppliers often leads to long lead times, high costs, and the need to order in large quantities to make production cost-effective. This dependency on external suppliers can cause delays and hinder a company’s ability to respond quickly to demand.</p><p><br></p><p><strong>The Solution: Metal 3D Printing for Fast and Flexible Production</strong></p><p>To address these challenges, One Click Metal turned to their in-house Laser Powder Bed Fusion technology. By utilizing metal 3D printing, they were able to produce the driver components much faster and with greater flexibility than traditional methods would allow. This approach eliminated the long lead times typically associated with external suppliers, allowing the company to quickly produce the parts they needed, when they needed them.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731664085880-2.png" style="width: 524px;" class="fr-fic fr-dib"></p><p>A significant advantage of using metal 3D printing in this scenario was the ability to maximize production efficiency. By stacking 144 drivers on a single build plate, One Click Metal could produce a large batch of components in just over 60 hours. This capability not only met the immediate production needs but also reduced the cost per part to €11.05—a significant savings compared to traditional manufacturing costs.</p><p><br></p><p><strong>Benefits of Metal 3D Printing in Meeting Production Demands</strong></p><p><br></p><ol><li data-list-indent="1" data-list-type="numbered"><p><strong>Rapid Production</strong>: Metal 3D printing enabled One Click Metal to produce a large number of components quickly, without the delays associated with traditional supply chains. This allowed the company to respond swiftly to production needs.</p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Cost Efficiency</strong>: By producing the parts in-house and utilizing the full build volume of the printer, the cost per driver was significantly reduced, making metal 3D printing a cost-effective option even for serial production.</p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Supply Chain Independence</strong>: With the ability to produce components on-demand, One Click Metal reduced its reliance on external suppliers, which is particularly beneficial when quick turnarounds are required.</p></li><li data-list-indent="1" data-list-type="numbered"><p><strong>Material and Design Efficiency</strong>: The LPBF process allowed for precise control over material usage, reducing waste and enabling the production of lightweight, optimized designs that still met all functional requirements.</p></li></ol><p><br></p><p><strong>Conclusion: Metal 3D Printing as a Versatile Manufacturing Tool</strong></p><p>The production of the driver component for the BOLDseries is a clear example of how metal 3D printing can be effectively used not only for unique, complex parts but also for the quick, repeated production of essential components. By leveraging this technology, manufacturers can gain greater control over their production processes, reduce dependency on suppliers, and achieve cost and time savings. Metal 3D printing proves to be a versatile tool that can meet a wide range of manufacturing needs, including those that require speed and flexibility.</p>

In manufacturing, the ability to quickly produce high-quality components on demand is critical. While metal 3D printing is often associated with producing unique, complex parts, its potential for serial production is frequently overlooked.

Fast and Repeated Production with Metal 3D Printing

<p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://fast.wistia.net/embed/iframe/wzpbp2p82h" width="900" height="450" allowtransparency="true" frameborder="0" scrolling="no" class="wistia_embed fr-draggable" name="wistia_embed" allowfullscreen="" mozallowfullscreen="" webkitallowfullscreen="" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span></p><p>Our <em>Insight</em> video series will help you master digital manufacturing.</p><p>Every Friday we’ll post a new video – each one giving you a deeper <em>Insight</em> into how to design better parts. We’ll cover specific topics such as choosing the right 3D printing material, optimising your design for CNC machining, surface finishes for moulded parts, and much more besides.</p><p>So join us and don’t miss out.</p><p id="isPasted"><strong>Transcript</strong></p><p>Hi, it’s Friday, which means it’s time for another Insight video.</p><p>Today I’m going to talk you about the super allow Inconel 718 and how 3D printing technology has really opened up how you can use this material.</p><p>But first of all, why is it known as a superalloy? Well quite simply it can cope in extreme environments where other metals would struggle or even not cope at all. Inconel can be permanently used in applications of over 600<sup id="isPasted">o</sup>C retaining its high strength and toughness plus corrosion resistance. It is also very light. In these environments, aluminium and steel would succumb to creep and copper would simply melt away.</p><p id="isPasted">And it is equally good in extreme low temperatures and is used in cryogenic environments where it helps prevent parts from becoming brittle, while again retaining its toughness.</p><p>This nickel and chromium mix is truly the Superman of the metal alloy world.</p><p>You won’t be surprised to learn that it is used extensively in aerospace applications where it can account for up to 50% of the weight of a turbojet engine. It is the main component for discs, blades and casings of the high-pressure section of the compressor and discs, plus some of the blades of the turbine engine.</p><p>In fact, without access to superalloys like Inconel, aerospace would probably not have advanced to the extent that it has today.</p><p id="isPasted">And it’s not just the aerospace industry where this superalloy stars, it is a common material for extreme environments in heavy industry as well.</p><p>First produced in the 1940’s if you fast forward to today, we have materials that evolved from those early superalloys. Today Inconel 718 is the world’s predominant superalloy. Its strength is derived from its ability to create a thick stable passivating oxide layer at temperatures as high as 704<sup>0</sup>C protecting the material from attack and retaining its good tensile, fatigue, creep and rupture strength.</p><p>What an amazing material.</p><p>Unfortunately, it is so amazing that there is not much that can touch it – so it’s extremely hard to machine requiring expensive tooling that reach very high temperatures on the edge of the machining insert. That and Inconel’s abrasive nature leads to high wear rates, chipping, notching and the cutting edge breaking on the tool.</p><p>Other traditional manufacturing methods when applied to Inconel 718 often end up sacrificing the very properties that you want in order to obtain the desired shapes.</p><p>Now, thanks to advances in 3D printing using direct metal laser sintering, or DMLS, there is no need to compromise. It also means that using this additive manufacturing technology, which builds a series of very fine layers on top of each other using a laser to melt the metal powder to the next layer, you can design even the most complex and intricate of designs – perhaps to save weight for example.</p><p id="isPasted">The process preserves Inconel 718’s mechanical properties and with its directional solidification it can help exceed the mechanical properties of the material’s cast and wrought counterparts.</p><p>And the other thing of course is that DMLS is an additive process. Inconel 718 is not cheap, you don’t get all of those amazing properties for nothing! Using DMLS will significantly cut down on your waste of this precious material. This layer wise building of components with near final contours produces only about 5% waste. In the aerospace industry they would say that this improves its “buy to fly” ratio.</p><p>Like anything of course Inconel does have some limits, just like superman and kryptonite.</p><p id="isPasted">In this case however we are talking about its geometric limits when using DMLS to produce parts. Let’s quickly run through them now.</p><p>First there is a minimal wall thickness of 1.00 millimetre and a minimum feature size of 1 mm, which is actually pretty small when you think about it.</p><p>If you need embossed details, then these must be at least 0.5mm high and wide and 0.8mm for text and images.</p><p>For engraved details you will be looking at a minimum of 0.5 mm depth and 0.6 mm width increasing to a minimum of 1.00mm width for text and images.</p><p>Also, because the part is formed in a chamber and needs support structures, there is a maximum part size. For us at Protolabs that is 245 by 245 by 300mm.</p><p>Now these restrictions will vary from supplier to supplier, so the best thing to do as always is to talk to them, find out what is possible and weigh up your options.</p><p>So, to pinch a cliché, when the going gets tough for your part, consider turning to Inconel 718. It is the superalloy of choice for many applications and now that it can be produced using 3D printing you can design almost anything you want.</p><p>Right that’s about it for this week. Have a great weekend and I’ll see you again next Friday.</p>

Your masterclass in product design and development.

3D Printing Inconel

<p id="isPasted">Sintering is the process of applying heat and/or pressure to fuse bits of metal, ceramic, and other materials into a solid mass. It’s nothing new. Nature has been fusing sedimentary minerals into slate and quartzite for eons, and humans began using similar methods to make bricks and porcelain millennia ago. Today, sintering is used to produce everything from gears and connecting rods to sprockets and bearings. It’s also used to <a href="https://www.protolabs.com/en-gb/services/3d-printing/" title="3D Printing" target="_blank">3D print</a> parts.</p><p><a href="https://www.protolabs.com/en-gb/services/3d-printing/selective-laser-sintering/#Design_Guidelines:_Selective_Laser_Sintering" title="Selective Laser Sintering" data-anchor="#Design_Guidelines:_Selective_Laser_Sintering" target="_blank">Selective laser sintering (SLS)</a> is a close cousin to <a href="https://www.protolabs.com/en-gb/services/3d-printing/direct-metal-laser-sintering/" title="Direct Metal Laser Sintering" target="_blank">direct metal laser sintering (DMLS)</a>, but builds parts made of plastic rather than metal. SLS uses a computer-controlled CO2 laser versus an ND: YAG fibre laser for DMLS, but both “draw” slices of a CAD model in a bed of material, fusing micron-sized particles of material one layer at a&nbsp;time.</p><p>SLS needs none of the support structures typical with DMLS, however, and unlike <a href="https://www.protolabs.com/en-gb/services/3d-printing/stereolithography/" title="Stereolithography" target="_blank">stereolithography (SL)</a>—the third laser-based additive manufacturing (AM) process available at Protolabs—SLS creates fully functional parts using engineering-grade nylon. This makes it an excellent way to prototype <a href="https://www.protolabs.com/en-gb/services/injection-moulding/" title="Injection Moulding" target="_blank">injection-moulded</a> products, and can even be used as a low-volume alternative to moulding in some cases.</p><h3>Rooted in Nylon</h3><p>As with any additive process, it’s important to understand the many design considerations applicable to SLS. One of these is the material. Despite their wide-ranging uses, all SLS parts are currently limited to nylon materials—the same thermoplastics used in fasteners, flak jackets, frying pans, and thousands of other everyday items. Protolabs offers six different materials (five different polyamides and one TPU):</p><ul><li><strong>PA 12 Smooth White/ Vapour Smooth White&nbsp;</strong>is an economical material choice for functional prototypes and end-use parts. It offers high impact and temperature resistance, is very durable, and remains stable under a range of environmental conditions. The nylon material exhibits a white finish with a slightly rougher surface texture compared to other nylons.</li><li><strong>PA 12 Glass Filled Smooth White</strong> is a polyamide powder loaded with glass spheres that add stiffness and dimensional stability. The material possesses higher thermal resistance than unfilled polyamides and exhibits excellent long-term wear resistance. Due to the glass additive, it has decreased impact and tensile strengths compared to other nylons.</li><li><strong>PAx Smooth Natural/ Vapour Smooth Natural</strong> is a versatile polyamide which is characterised by excellent toughness and flexibility in any direction, including the z plane. The material possesses great long term stability and durability and can be used to produce both prototyping as well as end-use parts.<br>The material is very versatile, so applications range from living hinges and snap fits to fixtures, enclosures as well as orthotics.</li><li><strong>PA 12 Carbon Filled Smooth Black</strong> is an anthracite grey nylon characterised by extreme stiffness and high-temperature resistance, coupled with electric conductivity properties and lightweight. It can be used for both functional prototypes and end-use parts. The carbon-fibre filler provides different mechanical properties based on the considered three-axis direction. This material exhibits a good surface quality and smoother finish compared to other SLS nylons.</li><li><strong>PA 12 Flex Flex Pure Black</strong> PA 12 Flex Black is a black / anthracite nylon characterised by excellent flexibility and impact resistance. PA 12 Flex Black combines positives properties of PA12 and PP. Strength and stiffness is similar to PA 12. The elongation is comparable to that of unfilled PP. Its high durability makes it an excellent choice not only for prototyping, but also for end-use parts.</li><li><strong>TPU-88A Pure Black</strong> is an anthracite grey nylon characterized by extreme stiffness and high-temperature resistance, coupled with electric conductivity properties and lightweight. It can be used for both functional prototypes and end-use parts. The carbon-fibre filler provides different mechanical properties based on the considered three-axis direction. This material exhibits a good surface quality and smoother finish compared to other SLS nylons.</li></ul><h3>Managing the Build</h3><p>These nylon materials cover many different applications.&nbsp;Most of the SLS material consumed at Protolabs is Nylon 12, however many customers are selecting bstiffer materials (the carbon-and glass-filled variants) or more flexible ones (TPU) based on their unique part requirements.&nbsp;There’s far more to effective part design than material selection, however, and controlling the in-build curl and post-build warping common with AM is paramount to good part quality.</p><p>Much of this control falls to Protolabs. To keep parts straight and true, our technicians will often tip parts slightly in the build chamber. If you’re designing a case for a handheld video game, for example, a compound incline of 10 to 15 degrees in the X and Y axes during the build is probably all that’s needed to keep the walls square and the box lid fitting smoothly. It’s important to point out that some “stair stepping” may occur as a result of this technique, so it’s important to identify cosmetic surfaces when submitting your design to Protolabs for quoting and&nbsp;analysis.</p><p>For especially challenging parts, ribs can be used to strengthen large, flat surfaces—if your handheld game design requires a thin lid, a honeycomb or checkerboard pattern on the inside surface will not only strengthen the lid, but also reduce material cost and potential&nbsp;warping.</p><p><img alt="Example of radiused corners" src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731598145938-1731598145937.png" class="fr-fic fr-dii" style="width: 322px;"></p><p skip="true"><em>Radiused corners, shown here, can be added to reduce stress.</em></p><h5>It’s Never Too Early to Improve Mouldability</h5><p>Many of the rules applied in injection moulding also apply to SLS, making it a solid choice for parts that will eventually be moulded. The use of hole bosses and support struts, and avoiding thick cross-sections are good practices for either manufacturing process. Additional design considerations include:</p><ul><li>Adding corner radii where walls meet to reduce stress</li><li>Uniform wall thickness—between 1.5mm and 3.8mm is recommended to reduce in-build curl and potential for warping</li><li>Integrating ribs to reduce warping</li></ul><p>Where injection-moulded parts can contain overmoulded metal bushings or threaded inserts, SLS parts achieve comparable functionality via heat-stake inserts—in our handheld game example, threaded inserts can be heat-staked as a secondary process at each corner of the housing for strong assembly&nbsp;purposes.</p><h3>Look and Feel</h3><p>The surface finish produced by SLS is a bit rougher than other AM technologies—anywhere from 100-250 RMS—but it still works reasonably well for most functional prototypes. Protolabs also bead blasts the majority of customers’ parts to remove loose powder and create a smooth matte finish. Very fine text is another consideration—since the minimum feature size with SLS is 1mm, very small fonts tend to get jammed with powder, making letters and numbers less legible. Moving to inset text provides better results, but is still limited to features no smaller than approximately 0.5mm. Lastly, SLS is slightly less accurate than competing laser sintering processes—where DMLS has expected tolerances of ±0.01mm plus an additional 0.001 mm/mm on metal parts, ±0.25mm plus ±0.0015mm is typically achievable with SLS. On well-designed&nbsp;parts.</p><p>The upside here is that SLS has a build frame of 700mm by 380mm by 580mm, far larger than its metal-making sidekick. And because there are no support structures involved, the entire powder bed can be utilized, making it easy to nest multiple parts into a single build. This makes SLS a solid alternative to machined plastic, a logical stepping-stone to injection moulding, and an excellent way to produce functional nylon parts in higher volumes than is usually associated with AM.</p>

SLS builds precise plastic parts for prototyping and low-volume production.

3D Printing Functional Parts with Selective Laser Sintering

<p id="isPasted">In <a href="https://xometry.eu/en/cnc-machining/" target="_blank" rel="noreferrer noopener">traditional manufacturing</a> and <a href="https://xometry.eu/en/3d-printing/" target="_blank" rel="noreferrer noopener">additive manufacturing</a>, the design and production phases are often the main focus. However, end products, whether they are industrial machines or electronic devices, often require post-processing to enhance their appearance or durability characteristics.</p><p><a href="https://xometry.pro/en-eu/articles/post-processing-eu/">Post-processing</a> in traditional manufacturing includes machining, polishing, and coating to smooth surfaces, remove excess material, or apply protective finishes. Additive manufacturing employs specific methods like support removal, surface smoothing, spray painting, and curing. For instance, resin 3D prints require UV light or heat post-curing to solidify and enhance their mechanical properties.</p><p>But what impact does post-processing have on the dimensional accuracy of parts? Will the part expand or contract? These are critical questions to consider when creating a 3D model to ensure that the part meets design specifications, functions correctly, and fits together seamlessly.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731520083327-vapor-smoothed-part-accuracy-1536x1152.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Measuring the accuracy of a vapor-smoothed 3D-printed part using a digital caliper.</span></span></span></p><h2 data-counter-attr="value0" id="isPasted"><strong>Common Post-Processing Techniques in Manufacturing</strong></h2><p>In designing, post-processing is important since it enhances part aesthetics as well as functionality. This also implies that it affects dimensional accuracy. There are several typical post-processing methods which are employed in CNC machining, sheet metal fabrication, and 3D printing:</p><ul><li><strong>Bead blasting:</strong> This technique uses a high-pressure stream of small beads, often made from glass or plastic, directed at the surface of the part, removing any faults it has and making it even all over. The process can smooth sharp edges slightly, thereby possibly changing key dimensions, particularly where intricate detail abounds.</li><li><strong>Electropolishing:</strong> This is an electrochemical method that removes very thin layers from steel, ensuring shiny surfaces after cleaning. However, the removal process produces bluntness, and results in minimal adjustments to fit precision requirements due to dimension changes.</li><li><strong>Vapor smoothing:</strong> Vapor smoothing involves bringing objects created from 3D printing in contact with chemical vapors, resulting in melting and regulating the outer surfaces. This process may alter small features and round off sharp edges, particularly for finely detailed parts.</li><li><strong>Media tumbling:&nbsp;</strong>In addition to burr removal, media tumbling also polishes surfaces through placing them into vibratory containers fitted with abrasive media. This process is not suitable for fragile part features like sharp edges.</li><li><strong>Sandblasting:</strong> Sandblasting uses high-speed particles for cleaning surfaces as well as texturing prior to painting or other treatments.</li><li><strong>Powder coating:</strong> Here, dry powders are applied electrostatically onto an object that will then be heated to cure the coat into a long-lasting one. However, the process increases dimensions slightly and may cause trouble in fitting tight components together.</li><li><strong>Plating:</strong> Plating involves depositing a metallic coating onto a surface to enhance electrical conductivity, wear resistance, and corrosion protection.</li><li><strong>Anodizing:</strong> Anodizing, which comes in different types (Type II and Type III being the most commonly used), is an electrochemical process used for increasing the oxide layer on metal surfaces.</li><li><strong>Passivation:</strong> This is the process by which stainless steel parts are treated to remove free iron and obtain better resistance to corrosion through the formation of a protective oxide layer.</li><li><strong>Spray painting:</strong> This process is used to apply paint to parts for aesthetics and protection, potentially altering dimensions slightly.</li></ul><section><p>Some post-processing methods can be combined for enhanced results, such as vapor smoothing followed by spray painting to achieve a smooth, colored surface, or sandblasting followed by anodizing for a matte, corrosion-resistant finish.</p><h2 data-counter-attr="value1" id="isPasted"><strong>How Different Post-processing Techniques Impact Dimensional Accuracy</strong></h2><p>When considering post-processing for parts, it is important to understand how each technique impacts both dimensional accuracy and surface finish. The table below compares different post-processing methods (all available on <a href="https://get.xometry.eu/?locale=en" target="_blank" rel="noreferrer noopener">Xometry’s Instant Quoting Engine®</a>), including their effects on the material’s dimensional accuracy and the typical surface finish you can expect.</p><table><thead><tr><th>Technique</th><th>Dimensional Change</th><th>Surface Finish</th><th>Typical Applications</th><th>Materials They Work With</th></tr></thead><tbody><tr><td>Bead Blasting</td><td>Negligible&nbsp;</td><td>Matte/satin,<br>grainy</td><td>Aesthetic finishing, surface<br>preparation for coatings</td><td>Metals, plastics,<br>composites</td></tr><tr><td>Electropolishing</td><td>Slight reduction (0.00635 mm)</td><td>Bright, smooth</td><td>Improving corrosion resistance and smoothing out micro-peaks and valleys</td><td>Stainless steel, aluminium, copper</td></tr><tr><td>Vapor Smoothing</td><td>Minor reduction (~0.023 mm)</td><td>Glossy, smooth</td><td>Enhancing surface quality of 3D printed parts</td><td>Thermoplastics</td></tr><tr><td>Media Tumbling</td><td>Negligible</td><td>Satin-like finish</td><td>Parts with smoothed surface</td><td>Metals, plastics</td></tr><tr><td>Sand Blasting</td><td>Slight reduction (~0.005–0.025 mm)</td><td>Dull finish</td><td>Surface preparation for paint</td><td>Metals, plastics</td></tr><tr><td>Powder Coating</td><td>Addition (~0.02–0.05 mm)</td><td>Matte or glossy, colored</td><td>Wear-resistant parts, aesthetics</td><td>Metals, plastics</td></tr><tr><td>Plating</td><td>Addition (~0.005–0.025 mm)</td><td>Metallic finish</td><td>Electrical components, wear-resistant parts</td><td>Metals (e.g., copper, nickel)</td></tr><tr><td>Passivation</td><td>Negligible</td><td>Matte, enhanced resistance</td><td>Aesthetic enhancements, surface protection</td><td>Stainless steel</td></tr><tr><td>Spray Painting</td><td>Addition (~0.02–0.1 mm)</td><td>Smooth, colored</td><td>Surface enhancement and protection&nbsp;</td><td>Metals, plastics</td></tr><tr><td>Anodizing (Type II)</td><td>Addition (~0.0025 mm)</td><td>Matte or glossy, colored</td><td>Corrosion resistance, durable parts</td><td>Aluminium</td></tr><tr><td>Anodizing (Type III)</td><td>Addition (~0.025 mm)</td><td>Matte or slightly rough, colored</td><td>High-wear applications, mechanical components, corrosion resistance, &nbsp;durable parts</td><td>Aluminium</td></tr><tr><td>Spray painting and vapor polishing</td><td>Addition (~0.012–0.25 mm); slight reduction (negligible)</td><td>Smooth, colored; Glossy, smooth</td><td>Combining surface enhancement/protection and quality improvement for 3D printed parts</td><td>Thermoplastic</td></tr><tr><td>Sand blasting and anodizing</td><td>Negligible reduction (~0.0025–0.025 mm)</td><td>Matte or satin, grainy; Matte or glossy, colored</td><td>Surface preparation and protection for aluminium parts</td><td>Aluminum</td></tr></tbody></table><h2 data-counter-attr="value2"><strong>Regulations and Standards for Maintaining Dimensional Accuracy During Post-processing</strong></h2><p>Here is a brief overview of standards related to dimensional accuracy maintenance during post-processing commonly used in Europe, the UK and Turkey:</p><table><thead><tr><th>Standard</th><th>Usage</th><th>Objective</th><th>Example of Application</th></tr></thead><tbody><tr><td><a href="https://www.iso.org/standard/7748.html" target="_blank" rel="noopener">ISO 2768</a></td><td>Establishes general tolerances for linear dimensions, angular dimensions, and geometrical tolerances in unassociated metal parts</td><td>Ensures consistency in size throughout different manufacturing processes and post-production stages</td><td>Indicating medium tolerances for a CNC-machined metal shaft with a 50 mm diameter as “ISO 2768-m” on the drawing</td></tr><tr><td><a href="https://www.iso.org/standard/66777.html" target="_blank" rel="noopener">ISO 1101</a></td><td>Sets permissible limits for variations in part geometry, focusing on form and position tolerances</td><td>Ensures components meet geometric standards despite dimensional changes during finishing operations</td><td>Specifying perpendicularity: ⊥ 0.1 ISO 1101 for a hole to remain within a 0.1 mm tolerance zone relative to a given datum plane</td></tr><tr><td><a href="https://www.gdandtbasics.com/asme-y14-5-gdt-standard/" target="_blank" rel="noopener">ASME Y14.5</a></td><td>Describes how GD&amp;T symbols specify allowable variations in sizes and shapes of parts using controls such as position control</td><td>Ensures uniformity and high accuracy during and after manufacturing</td><td>Using positional tolerance symbol on the drawing:&nbsp;Position: Ⓟ 0.2 | ⌀10 | A B C*</td></tr><tr><td><a href="https://www.astm.org/d0618-21.html" target="_blank" rel="noopener">ASTM D618</a></td><td>Describes the practice for conditioning plastics for testing purposes after molding to test for thermal or chemical smoothing effects</td><td>Ensures dimensional accuracy by conditioning samples for equilibrium before further operations</td><td>Conditioning plastic samples for 48 hours at 50°C, then 96 hours at 23°C with 50% relative humidity before chemical smoothing</td></tr></tbody></table><p>*The center of the hole must fall within a zone of 0.2mm diameter about datums ‘A,’ ‘B,’ and ‘C’ so that accurate assembly can be achieved during post-processing.</p><h2 data-counter-attr="value3"><strong>Tools and Technology for Monitoring and Controlling Dimensional Changes</strong></h2><p>Monitoring/controlling dimensional changes during post-processing requires accurate tools/technologies. Some key solutions include:</p><ul><li><strong>Coordinate Measuring Machines (CMMs):</strong> These machines use a probe to accurately measure the physical shapes of an object. They are useful for checking measurements as well as detecting any deviation from design specifications. They excel in precision, often achieving measurements within micrometers (0.001 mm), far surpassing the typical accuracy of digital calipers, which is around 0.01 mm.</li><li><strong>Laser scanners:</strong> Laser scanners provide non-contact measurement. They generate high-resolution 3D models of parts that are then compared to CAD designs to ascertain any dimensional change.</li><li><strong>Optical comparators:</strong> These devices project the profile of a part onto a screen and allow for visual comparison against pre-set standards. They are most useful in monitoring dimensional changes in small and intricate parts.</li><li><strong>Digital calipers and micrometers:</strong> For fast, accurate measurements, digital calipers and micrometers provide excellent accuracy when it comes to measuring lengths or thicknesses, which is imperative for quality control.</li><li><strong>Surface roughness testers:</strong> These determine surface finish quality by identifying changes that would affect dimensional accuracy resulting from practices like sanding or polishing through post-processing.</li></ul><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731520160516-engineer-using-cmm-measuring-3d-printed-part-close-up-1536x1024.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Engineer inspecting a part using a coordinate measuring machine (CMM) for dimensional accuracy</span></span></span></p><h2 data-counter-attr="value4" id="isPasted"><strong>How to Reflect Tolerances on Technical Drawings</strong></h2><ul><li>To reflect the finishing processes, such as anodizing, on technical drawings, it is necessary to indicate post-treatment tolerances for any specific customer requirement (e.g. hard anodizing 50µm).&nbsp;</li><li>Clearly specify on the drawing that tolerances on the drawing are&nbsp;<strong>post-treatment</strong>.</li><li>For thin treatments (&lt;10 µm), final tolerances can often be assured. For any treatments thicker than 10 µm, it is recommended to mask certain surfaces to prevent unpredictable dimensional changes post-treatment (e.g. mask threaded holes to ensure they remain within tolerance and functional after a thick anodizing layer is applied).</li><li>Add any surface finish symbols (roughness) and specific tolerances (linear or geometric) that will ensure the part meets its functional requirements.</li></ul></section>

This article will discuss the different post-processing methods and their impact on dimensional accuracy, helping you navigate potential challenges and ensuring your designs achieve the precision and quality they require.

Impact of Post-Processing on Dimensional Accuracy of Parts

<p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe width="640" height="360" src="https://www.youtube.com/embed/1pLhHg2N34Q?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><br></p><p id="isPasted">Kapsula is an innovative solution designed to provide extreme protection for electronic devices in harsh environments. Utilizing advanced materials like polyphenylene sulfide reinforced with carbon fiber (PPS CF), Kapsula offers unparalleled durability against physical impacts, high temperatures, and environmental stressors.</p><p>This robust protection ensures the integrity and functionality of critical electronic equipment and vials containing medicines or biological samples, making Kapsula essential for both civilian and military applications.</p><p>Despite its high resistance, Kapsula remains lightweight at only 250g and can be produced cost-effectively via 3D printing, allowing for on-site manufacturing even in war zones. Kapsula can be deployed in various ways, including drone drops from significant heights or carried by personnel due to its ergonomic design.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731519472292-kapsula-10.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h4 id="isPasted">Technical Approach</h4><p>Kapsula is designed as a 3D printed truncated icosahedron, using PPS CF material for high strength and thermal stability. It features a TPU core with a gyroid fill pattern for impact absorption, structural textures for reinforcement, and customizable internal shells.</p><p>The truncated icosahedron was selected due to its superior mechanical properties. This shape is renowned for its ability to evenly distribute forces, minimizing stress concentrations that could lead to material failure.</p><p>The 3D printer used is the new UltiMaker Factor 4, specifically designed to print challenging materials such as PPS CF.</p><p>Advanced features include an integrated GPS sensor and potential additional electronic countermeasures.</p><h4>Ergonomic Design and Manual Operation</h4><p>Kapsula's design is not only robust but also ergonomic. It is small enough to fit comfortably in one hand, making it easy to carry and manipulate.</p><p>The capsule features a simple manual opening mechanism, designed to be operated without tools, ensuring quick and easy access in the field.</p><p>This "rustic" approach to opening means that soldiers and field personnel can rapidly deploy the device without needing specialized equipment.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731519509529-1731519509529.png" class="fr-fic fr-dib"></p><h4 id="isPasted">Advanced Internal Features</h4><p>Inside, Kapsula can include a layer of thermoplastic polyurethane (TPU) printed with a gyroid fill pattern. This gyroid structure is particularly effective at absorbing impacts, providing an additional layer of protection for the electronic devices housed within.</p><p>The TPU core acts as a shock absorber, preventing damage from drops and other impacts.</p><p>This internal design can be customized to fit various objects, ensuring optimal protection for a wide range of equipment.</p><h4>Structural Textures and Reinforcements</h4><p>To further enhance its durability, Kapsula incorporates structural textures applied to its internal surfaces. These textures are designed to reinforce the model, increasing its resistance to impacts and environmental stressors.</p><p>The textures and topologies are carefully calculated and designed to maximize strength while minimizing weight, ensuring that Kapsula remains both lightweight and incredibly strong.</p><p>It can be scaled to different sizes to accommodate various applications and can be enhanced with an intermediate metal layer for additional resistance.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731519534588-kapsula-6.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h4 id="isPasted">Development Status</h4><p>Prototype: successfully demonstrated in relevant environments, including high-temperature and high-impact scenarios (drone drop).</p><p>Testing: conducted in various conditions to validate performance claims. Ongoing test campaigns include extended environmental exposure and cyber-physical stress testing.</p><h4>Multiple use potential</h4><p>Kapsula effectively meets both military and civilian needs. In military contexts, it protects battlefield communication devices, ensuring reliable data transmission and preventing data loss during combat. Its lightweight, drone-compatible design allows for the safe delivery of sensitive equipment or supplies to remote locations.</p><p>Additionally, Kapsula acts as a durable black box for drones, safeguarding data in crashes.</p><p>For disaster response or civilian use, Kapsula ensures continuous operation of monitoring equipment and safe transport of medical samples, biological specimens, or evidence requiring secure handling or drone delivery.</p><p>In commercial applications, it protects industrial equipment from hazards.</p>

Kapsula is an innovative solution designed to provide extreme protection for electronic devices in harsh environments. Utilizing advanced materials like polyphenylene sulfide reinforced with carbon fiber (PPS CF), Kapsula offers unparalleled durability against physical impacts, high temperatures

Kapsula: Extreme Protection for Sensitive Devices

<h2 id="isPasted">Project overview</h2><h3>Purpose</h3><p>The purpose of this project was to demonstrate the multilayer capability of <a href="https://www.voltera.io/nova">Voltera NOVA</a>. We printed a blue light-emitting pattern — the Voltera logo — on two substrates: paper and PET separately, using electroluminescent ink.</p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/Yc8nEoVnpDY?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 450px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h3 id="isPasted">Design layout</h3><p>Electroluminescence operates by exciting a phosphor material with an electric field. An inverter is needed to convert the direct current from the power source into alternating current.</p><p>Based on this mechanism, our design positions a phosphor layer between two conductive layers, incorporating a dielectric ink layer to insulate the phosphor. The printing sequence is as follows:</p><ul><li>Layer 1: Base conductive layer&nbsp;</li><li>Layer 2: Dielectric layer&nbsp;</li><li>Layer 3: Phosphor layer</li><li>Layer 4: Top conductive layer</li></ul><h3>Layer overview</h3><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492862692-67091c8ba38b9d9305e349bd_67091ae09acab270adbdf20e_Printing-electroluminescent-ink-paper-pet-layer-overview.webp" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Desired outcome</h3><p>Once connected to an alternating current (140 V, 1.862 kHz), the phosphor layer emits blue light, illuminating the Voltera logo with an even glow across both prints.</p><h3>Functionality</h3><p>We determined the Voltera logo would be suitable for this project. It is feasible to incorporate designs into larger electronic applications, including billboards, branded merchandise, and control panels.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492887115-67091c8ca38b9d9305e34a1b_67091b02bdc7f308274e583c_Printing-electroluminescent-ink-paper-pet-functionality.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Final print on paper<br></span></span></span></p><h2 id="isPasted">Printing the electroluminescent Voltera logo</h2><h3>Base conductive layer</h3><p>This layer consists of a Voltera logo pattern (55.5 mm L × 19.75 mm W) and positive and negative traces that connect to power and ground terminals.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492929241-67091c8ba38b9d9305e349c3_67091b1d9aa70f5ad577fd0b_Printing-electroluminescent-ink-base-conductive-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, base conductive layer<br></span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492948899-67091c8ba38b9d9305e349d2_67091b3ba4c7564aec9fc4c0_Printing-electroluminescent-ink-base-conductive-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, base conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731492971049-67091c8ca38b9d9305e34a00_67091b566f34a25480b46ae4_Printing-electroluminescent-ink-base-conductive-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, base conductive layer</span></span></span></p><h3 id="isPasted">Dielectric layer</h3><p>This layer features a dielectric Voltera logo pattern which measures 23 mm L × 15 mm W and two dielectric pads. These extra pads help ensure the top conductive layer is appropriately insulated.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493165129-67091c8ba38b9d9305e349c0_67091b7716905ac65aa4e290_Printing-electroluminescent-ink-dielectric-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, dielectric layer</span></span></span></p><h3><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493233623-67091c8ba38b9d9305e349cf_67091b9107b512cf5a4ae562_Printing-electroluminescent-ink-dielectric-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, dielectric layer<br></span></span></span></h3><h3><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493246956-67091c8ca38b9d9305e34a15_67091bafbdc7f308274eea1a_Printing-electroluminescent-ink-dielectric-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, dielectric layer</span></span></span></h3><h3 id="isPasted">Phosphor layer</h3><p>This layer contains a Voltera logo pattern, slightly smaller than the dielectric layer (by 0.5 mm each way), printed with blue light-emitting ink.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493315418-67091c8ba38b9d9305e349c9_67091bcf07c69e92aba81f70_Printing-electroluminescent-ink-phosphor-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, phosphor layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493337007-67091c8ba38b9d9305e349d5_67091be50886a22f6b31099d_Printing-electroluminescent-ink-phosphor-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, phosphor layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493358134-67091c8ca38b9d9305e34a1e_67091c028b83f4ea5977853c_Printing-electroluminescent-ink-phosphor-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, phosphor layer</span></span></span></p><h3 id="isPasted">Top conductive layer</h3><p>Lastly, this layer includes a conductive overlay with an opening at the bottom left to prevent short circuiting. It measures 29.5 mm L × 21.5 mm W and connects to the ground terminal.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493385109-67091c8ba38b9d9305e349db_67091c23c63ef691b7477c26_Printing-electroluminescent-ink-top-conductive-layer-settings.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: NOVA settings, top conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493412343-67091c8ca38b9d9305e34a12_67091c394819899b375fb8eb_Printing-electroluminescent-ink-top-conductive-layer-paper-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on paper, top conductive layer</span></span></span></p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493430542-67091c8ca38b9d9305e34a18_67091c534ec56a943f81fc4f_Printing-electroluminescent-ink-top-conductive-layer-pet-result.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Result on PET, top conductive layer</span></span></span></p><h2 id="isPasted">Challenges and advice for printing multilayer electroluminescent displays</h2><h3>Trapped air</h3><p>Air bubbles can form in inks that have been left unused for an extended period. These bubbles caused the dielectric layer to break when we cured it in the oven.&nbsp;</p><p>Mixing the ink with a dual asymmetric centrifugal mixer before printing will eliminate air bubbles. Additionally, it is recommended to allow the dielectric layer to dry naturally at room temperature instead of curing it in an oven.&nbsp;</p><h3>Uneven glow&nbsp;</h3><p>During our experiments, some prints exhibited dark areas, leading to an uneven glow. This issue can arise from several factors:&nbsp;</p><ul><li>The top conductive layer being too thick</li><li>The phosphor layer being too thin or getting scratched off during dispensing of the ink for the top conductive layer</li><li>Irregularities in print height</li></ul><p>Adding fiducials to each layer helps improve alignment and print quality. In terms of print settings, if the layer is too thick, increasing the print speed, reducing the height (we reduced it to approximately 40 µm), and using a smaller nozzle can be helpful. If the layer is too thin, try to reduce the print speed.&nbsp;</p><p>Furthermore, in multilayer projects, changes in height can happen drastically when printing over existing traces. Setting a low probe pitch will make the height map more accurate, ensuring the height transition at the edges of features is accurate and reducing the risk of traces being printed off-course.</p><h2>Conclusion</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1731493470103-67091c8ca38b9d9305e34a03_67091c71bdc7f308274f8ff7_Printing-electroluminescent-ink-paper-pet-conclusion.webp" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Image: Electroluminescent logo final print</span></span></span></p><p id="isPasted">The paper substrate provided consistent results throughout our experimentation, due to its absorbent nature. Each layer was smoother on paper than on PET, highlighting the potential of using paper as a substrate in EL display applications. &nbsp;</p><p>On the other hand, PET, being flexible and chemically resistant, offers the advantage of suitability for more demanding use cases. As demonstrated by this project, with careful attention and fine-tuning of the print settings, the results of EL display on PET are equally impressive.</p><p>EL displays are also intriguing when printed on glass and other non-conductive substrates. As we continue to explore the possibilities of electroluminescent inks, we invite you to view the&nbsp;<a href="https://www.voltera.io/applications">other projects</a> we’ve completed.</p>

Due to their consistent brightness, low cost and high energy efficiency, electroluminescent inks are used in a wide range of electroluminescent display applications. This project is an example of printing an electroluminescent ink on soft and flexible substrates.

Printing Electroluminescent Ink on Paper and PET

<p data-pm-slice="1 1 []" id="isPasted">Finishing techniques can enhance the surface quality, durability, and appearance of metal 3D printed parts, making them suitable for a wide range of applications. Here’s a look at some of the key finishing technologies used in metal additive manufacturing.</p><p><br></p><p><strong>Air Blasting</strong></p><p>Air blasting is a versatile finishing process that involves accelerating blasting materials through a nozzle to treat the surface of a metal part. This technique is commonly used to clean surfaces, remove residual powder from the 3D printing process, and alter surface roughness. By reshaping or removing material, compressed air blasting can enhance the texture of a part, making it smoother or more consistent. It is particularly useful for preparing parts for further finishing processes or improving their mechanical properties.</p><p><br></p><p><strong>Blackening</strong></p><p>Blackening is a specialized finishing technique primarily used on iron and steel components. The process involves creating a thin protective layer of black oxide on the surface of the metal, which helps to reduce rust and improve friction properties. Blackening not only enhances the aesthetic appeal of a part by giving it a darker, matte finish but also preserves its dimensions, making it a popular choice for parts that require both protection and precision. This technique is commonly used in firearms, tools, and other iron-based products.</p><p><br></p><p><strong>Gold plating</strong></p><p>Gold plating is the process of covering a metal surface with a layer of gold through electroplating. In this technique, the metal object is submerged in a gold electrolyte solution, and an electric current is applied to deposit a thin, uniform layer of gold onto the surface. Gilding is often used for decorative purposes, adding a luxurious appearance to metal parts. Additionally, it can provide a layer of corrosion resistance, making it a practical as well as an aesthetically pleasing finish for high-end applications.</p><p><br></p><p><strong>Anodizing</strong></p><p>Anodizing is a finishing process that creates a protective oxide layer on metal surfaces by converting the existing material rather than adding an external layer. This process involves submerging the part in an electrolyte solution and applying an electric current, which forms a thin, compact oxide layer on the surface. The thickness of this layer can be varied, resulting in different colors, from deep blacks to vibrant blues and reds. Anodizing is commonly used on aluminum parts to enhance corrosion resistance, improve wear resistance, and achieve a decorative finish.</p><p><br></p><p><strong>Nickel Plating</strong></p><p>Nickel plating involves applying a layer of pure nickel to a metal surface using electric currents. This process is widely used to protect metals such as iron and steel from corrosion while also enhancing their appearance. Nickel plating can be applied in varying thicknesses, making it suitable for both decorative applications and industrial uses where a durable, corrosion-resistant coating is needed. It is also commonly used as a base layer for other finishes or to improve solderability in electronic components.</p><p><br></p><p><strong>Polishing</strong></p><p>Polishing is a finishing process that smooths and refines the surface of a metal part through mechanical grinding and the application of polishing compounds. This process can remove material, round sharp edges, and fill in surface pores, resulting in a smooth, glossy finish that reflects light evenly. Polishing is often used to reduce friction on mechanical parts, enhance their aesthetic appeal, and prepare surfaces for further treatments such as plating or coating. It is an essential step in achieving a high-quality finish on metal 3D printed parts.</p><p><br></p><p>The finishing processes available for metal 3D printed parts offer a wide range of enhancements, from improved durability and corrosion resistance to aesthetic improvements and precise surface alterations. By selecting the appropriate finishing technique, manufacturers can ensure that their metal 3D printed parts meet the highest standards of quality and functionality, suitable for both industrial and consumer applications.</p>

Metal 3D printed Titanium bottle openers - anodized

Metal 3D printing enables the creation of complex and precise components directly from digital designs. To achieve desired aesthetic and functional qualities, the printed parts sometimes require finishing processes.

Enhancing Metal 3D Printed Parts: Finishing Technologies and Techniques

<p dir="ltr">Bioelectronics is a multidisciplinary field that combines biology and electronics to develop devices that interface with biological systems. It plays a crucial role in the healthcare industry as it enables innovations like advanced prosthetics, electronic skins (e-skins), and exoskeletons to improve the quality of life for individuals by restoring or enhancing bodily functions. This integration of biological systems with electronic devices is transforming healthcare by allowing for more personalized, efficient, and responsive treatments.</p><h2 dir="ltr">The Evolution of Bioelectronics</h2><h3 dir="ltr">From Concept to Application</h3><p dir="ltr">Bioelectronics emerged in the late 18th century with Luigi Galvani's experiments, which discovered that electricity could stimulate muscles, introducing the concept of "animal electricity." His work laid the foundation for understanding neuroelectricity. In the 1930s, electrical stimulation research led to the development of cochlear implants. The field gained momentum in the 1940s and 1950s when Alan Hodgkin and Andrew Huxley recorded action potentials in nerve cells, earning them a Nobel Prize in 1963.&nbsp;1</p><p dir="ltr">Currently, bioelectronics in medicine is considered to be a rapidly growing market.&nbsp;1&nbsp;Bioelectronics is currently being applied in various areas of healthcare, including wearable devices, implantable sensors, neural interfaces, and drug delivery systems. For instance, wearable electronics like health monitors and smart textiles are used to track vital signs in real time. Similarly, implantable devices, such as neural interfaces, facilitate direct communication between the brain and external devices.</p><h2 dir="ltr">Key Technologies in Bioelectronics</h2><p dir="ltr">The current state of bioelectronics became possible due to several advanced key technologies. For instance, flexible electronics technologies allow devices to conform to the body's contours to enhance user comfort and enable continuous monitoring. Sensors embedded within these systems can capture and relay physiological data. Similarly, biocompatible materials, like bioceramics, are compatible with the body and minimize adverse reactions.</p><p dir="ltr">Another important technology in this regard is additive manufacturing, specifically DIW, since it allows users to print electronic structures with biocompatible inks layer by layer with high precision, which helps develop complex biomedical devices tailored to individual patients.</p><h1 dir="ltr">Understanding Biocompatible Inks and Their Role in Bioelectronics</h1><h3 dir="ltr">What Are Biocompatible Inks?</h3><p dir="ltr">Biocompatible inks are specialized materials designed for safe interaction with biological systems which makes them significant in developing bioelectronics. These inks are typically composed of polymers, hydrogels, conductive materials like gold and silver-silver chloride, or other bio-friendly substances that can mimic the properties of living tissues, such as flexibility and conductivity. The primary role of biocompatible inks in bioelectronics is to create interfaces that can integrate smoothly with biological tissues, enabling innovations like flexible sensors, and implantable devices.</p><h3 dir="ltr">Biocompatible Inks in DIW Systems</h3><p dir="ltr">DIW technology is an advanced additive manufacturing method used to print electrical circuits, features, patterns, and traces by extruding ink from a fine nozzle in a precise and controlled manner. DIW can print biocompatible inks onto biocompatible substrates for in- or on-body monitoring and recording of bioelectric signals.&nbsp;</p><p dir="ltr">Moreover, DIW offers high precision and flexibility, making it ideal for creating customized biomedical solutions as it allows the users to tune various parameters, including extrusion pressure, nozzle speed, and material calibration, to tailor the printed material's properties to the specific needs of a patient.</p><h3 dir="ltr">Compatibility with Common Substrates</h3><p dir="ltr">DIW systems are highly versatile and allow precise dispensing of various materials with differing mechanical and electrochemical properties. This adaptability makes DIW well-suited for printing onto organic polymer substrates like PEDOT:PSS, which is a combination of two distinct polymers (poly(3,4-ethylenedioxythiophene) and polystyrene sulfonate).&nbsp;</p><p dir="ltr">PEDOT:PSS offers excellent electrical conductivity, flexibility, and biocompatibility, making it an ideal substrate for biosensing applications. This compatibility of PEDOT:PSS with DIW helps create complex, multifunctional devices where the electrochemical behavior of this substrate enhances the functionality of printed sensors, leading to innovative biomedical solutions.</p><h1 dir="ltr">On-Body and In-Body Bioelectronics: Current Applications and Future Prospects</h1><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzMwOTg0OTIxMDA0LUdvbGQgZWxlY3Ryb2RlIG9uIHNraW5fMS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 100%px;" class="fr-fic fr-dib"></p><p>Over the next decade, the bioelectronic technologies market is expected to witness significant growth, projected to expand from $23.9 billion in 2024 to approximately $33.6 billion by 2029, achieving a compound annual growth rate (CAGR) of 7.0%. This growth is expected due to the rising elderly population and increasing prevalence of cardiovascular and neurological disorders. Non-invasive electroceutical devices, such as on-body bioelectronics like transcutaneous electrical nerve stimulation (TENS) devices, and in-body bioelectronics like implantable neurostimulators, are anticipated to grow at the highest rate, driven by advancements in technology and increased research and development investments. 2</p><h2 dir="ltr">On-Body Bioelectronics</h2><p dir="ltr">On-body bioelectronics refers to electronic devices and systems that are designed to be worn directly on the skin or embedded into wearable materials to monitor, stimulate, or interact with biological processes in the human body. Wearable devices like smartwatches and fitness trackers that monitor heart rate, body temperature, and other vital signs in real time are among the most common applications of on-body bioelectronics. Similarly, smart textiles are another type of on-body bioelectronics that include fabrics integrated with electronic components that can measure biomechanical movements, making them advantageous in sports, rehabilitation, and clinical monitoring.</p><h2 dir="ltr">In-Body Bioelectronics</h2><p dir="ltr">In-body bioelectronics, like pacemakers, cochlear implants, and neural interfaces, are implanted or inserted within the human body to monitor physiological processes, deliver therapies, or interact with biological tissues at a deeper level. For instance, neural interfaces enable direct communication between the brain and external devices, providing a unique approach to treating conditions like Parkinson's disease and epilepsy.&nbsp;</p><h2 dir="ltr">Multifunctional Bioelectronics</h2><p dir="ltr">Multifunctional bioelectronics aims to combine several functions, such as drug delivery, diagnostics, and therapeutic interventions, into a single device, enhancing their biomedical applications. For instance, silk-based transient bioelectronics, powered by triboelectric nanogenerators (TENGs) enable real-time in vivo monitoring and therapeutic treatments. These systems are self-powered and biodegradable, with adjustable lifespans and sensitivity through silk molecular customization.&nbsp;3&nbsp;These multifunctional devices have the potential to revolutionize personalized medicine by providing more comprehensive health solutions.</p><h2 dir="ltr">Challenges&nbsp;</h2><p dir="ltr">Integrating bioelectronics into healthcare presents significant inherent regulatory and ethical challenges. As bioelectronic devices are advancing, especially those used in the medical industry like pacemakers and neural implants, the impact on users' health means that regulatory and ethical considerations are increasing in importance.</p><p dir="ltr">Ensuring the safety and efficacy of these devices requires rigorous testing and compliance with regulatory standards. Ethical considerations also arise regarding user privacy, data security, and informed consent, especially when sensitive health information is collected and shared. Addressing these challenges is crucial to building public trust and ensuring the responsible use of bioelectronics.</p><p dir="ltr">Moreover, although on-body bioelectronics are beneficial, there are also challenges in developing on-body bioelectronics, particularly regarding power supply, and user comfort. These challenges require innovative solutions, and some solutions, like <a href="https://www.voltera.io/application-whitepapers/printing-magnesium-zinc-battery-saral-inks-pet?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=mg-zn-battery-white-paper">flexible batteries</a>, have already made significant differences in tackling some of these challenges.</p><p dir="ltr">Biocompatibility is another key challenge in developing in-body bioelectronics as these devices are placed inside the body; they must be made from compatible materials that do not provoke immune responses and can operate without causing harm to surrounding tissues. Moreover, maintaining the device's functionality over time, despite the harsh environment within the body, which includes exposure to fluids, enzymes, and mechanical stresses, is also a significant challenge.</p><h2 dir="ltr">Opportunities and Emerging Trends: The Future of Bioelectronics</h2><p dir="ltr">Currently, one of the most compelling emerging trends in bioelectronics is the development of smart bioinks. These bioinks have enhanced functionalities, such as responding to environmental changes like temperature, pH, and chemical stimuli. For instance, smart bioinks can be designed to release therapeutic agents in response to specific stimuli, promoting targeted healing and enhancing treatment efficacy.&nbsp;4&nbsp;This adaptability of smart bioinks can lead to future bioelectronic devices that dynamically adjust to the body's needs, further improving their therapeutic potential.</p><h1 dir="ltr">Voltera's Role in Advancing Bioelectronics and Biocompatible Inks</h1><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/zsniZR1if1s?&amp;wmode=opaque&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 460px;" data-gtm-yt-inspected-24="true" id="654705223" title="Printing ECG Electrodes with Gold Ink on Voltera NOVA"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span><a href="https://www.wevolver.com/profile/voltera">Voltera</a> is a leading provider of advanced materials dispensing solutions for printing bioelectronics prototypes. Voltera's <a href="https://www.voltera.io/nova?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=nova-lp">NOVA</a> supports a wide range of materials, allowing researchers to test and experiment with various substrates and conductive inks. This flexibility allows innovation in bioelectronics, offering opportunities for breakthroughs in multifunctional bioelectronics devices. For instance, NOVA enables researchers to print biocompatible inks, such as gold and silver-silver chloride with exceptional precision to facilitate prototyping complex bioelectronics. This advanced system supports the development of traditional rigid electronics, as well as flexible hybrid electronics (flexible, stretchable, and conformable).&nbsp;</p><p dir="ltr">In particular, with a minimum line width of 100 µm and temperature-controlled dispensing, NOVA enables users to dispense biocompatible inks, pastes, gels, and adhesives on stretchable, soft, and flexible substrates, unlocking the ability to print bioelectronics that conform to the body’s natural contours.</p><h2 dir="ltr">Supporting Research and Innovation</h2><p dir="ltr">Researchers worldwide are using Voltera's tools to push the boundaries of bioelectronics. For example, in a 2024 <a href="https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta">study</a>, researchers utilized the Voltera’s NOVA PCB printer to fabricate organic electrochemical transistors (OECTs) as part of their investigation into electrochemical organic neuromorphic devices (ENODes). NOVA was employed to directly print transistors with specific PEDOT formulations onto glass substrates, enabling the precise patterning of silver feedlines and contact pads. The team achieved a compact design with a high degree of control over the devices' channel and gate structures, facilitating the integration of biocompatible gel-electrolytes. This method allowed the study to examine ENODe performance under varied electrolyte conditions, specifically focusing on short- and long-term plasticity for potential applications in brain-chip interfacing.5</p><p dir="ltr">Similarly, in another 2022 <a href="https://doi.org/10.1109/FLEPS53764.2022.9781535">study</a>, researchers utilized Voltera's NOVA to fabricate silver-based tattoo electrodes to monitor bioelectric signals. NOVA enabled precise extrusion printing of high-viscosity silver flake ink on porous tattoo paper, leading to electrodes with lower sheet resistance and better electrical performance compared to inkjet-printed alternatives. This improved efficiency by minimizing ink absorption into the substrate, and reducing impedance in bioelectrical measurements.&nbsp;6</p><p dir="ltr">These researches, along with many others, are a testament to Voltera's commitment to supporting the next generation of bioelectronic innovations. Voltera's products, like NOVA and V-One, ensure that the next generation of devices continues to improve the quality of life for patients worldwide.</p><h1 dir="ltr">Conclusion</h1><p dir="ltr">The importance of bioelectronics is self-evident, as these technologies have immense significance in advancing modern personalized medicine, real-time health monitoring, and patient outcomes, which ultimately have the potential to revolutionize the future of medicine. DIW technology is integral to these advancement as it enables precise prototyping of bioelectronic devices with biocompatible inks in both on-body and in-body applications.&nbsp;</p><p dir="ltr">The projected market growth of bioelectronics is up to $33.6 billion by 2029, which indicates that this field is rapidly advancing and holds immense potential to reshape the future of healthcare.</p><h2 dir="ltr">Explore the future of bioelectronics applications&nbsp;</h2><p dir="ltr">For researchers and engineers looking to explore the next frontier of bioelectronics, Voltera's platforms provide the tools and support necessary to advance the field. <a href="https://www.voltera.io/book-a-meeting?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=book-a-meeting">Book a call with Voltera</a> to learn how their technology can contribute to <a href="https://www.voltera.io/applications/bioelectronics?utm_campaign=Wevolver&utm_source=wevolver&utm_term=intersection-biology-technology-future-bioelectronics&utm_content=bioelectronics-application-page">your bioelectronics applications</a>.</p><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr">Stavrinidou, E., &amp; Proctor, C. M. (Eds.). (2022). Introduction to Bioelectronics: Materials, Devices, and Applications. AIP Publishing LLC. <a href="https://doi.org/10.1063/9780735424470_001">https://doi.org/10.1063/9780735424470_001</a></p></li><li dir="ltr"><p dir="ltr">Electroceuticals/Bioelectric Medicine Market worth $33.6 billion by 2029. [Online] Markets and Markets. Available at: <a href="https://www.marketsandmarkets.com/PressReleases/electroceutical.asp">https://www.marketsandmarkets.com/PressReleases/electroceutical.asp</a> (Accessed on September 4, 2024)</p></li><li dir="ltr"><p dir="ltr">Zhang, Y., Zhou, Z., Fan, Z., Zhang, S., Zheng, F., Liu, K., ... &amp; Tao, T. H. (2018). Self‐powered multifunctional transient bioelectronics. Small. <a href="https://doi.org/10.1002/smll.201802050">https://doi.org/10.1002/smll.201802050</a></p></li><li dir="ltr"><p dir="ltr">Maan, Z., Masri, N. Z., &amp; Willerth, S. M. (2022). Smart bioinks for the printing of human tissue models. Biomolecules. <a href="https://doi.org/10.3390/biom12010141">https://doi.org/10.3390/biom12010141</a></p></li><li dir="ltr"><p dir="ltr">Rana, D., Kim, C. H., Wang, M., Cicoira, F., &amp; Santoro, F. (2024). Tissue-like interfacing of planar electrochemical organic neuromorphic devices. Neuromorphic Computing and Engineering. <a href="https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta">https://iopscience.iop.org/article/10.1088/2634-4386/ad63c6/meta</a></p></li><li dir="ltr"><p dir="ltr">El-Hajj, Y., Ghalamboran, M., &amp; Grau, G. (2022, July). Inkjet and extrusion printed silver biomedical tattoo electrodes. In 2022 IEEE International Conference on Flexible and Printable Sensors and Systems (FLEPS) IEEE. <a href="https://doi.org/10.1109/FLEPS53764.2022.9781535">https://doi.org/10.1109/FLEPS53764.2022.9781535</a></p></li><li dir="ltr"><p dir="ltr">Voltera [Online] Wevolver, Available at: <a href="https://www.wevolver.com/profile/voltera">https://www.wevolver.com/profile/voltera</a> (Accessed on September 4, 2024)</p></li><li dir="ltr"><p dir="ltr">NOVA. The future of printed electronics [Online] Voltera, Available at: <a href="https://www.voltera.io/nova">https://www.voltera.io/nova</a> (Accessed on September 4, 2024)</p></li><li dir="ltr"><p dir="ltr">V-One. PCB prototyping made easy [Online] Voltera, Available at: <a href="https://www.voltera.io/v-one">https://www.voltera.io/v-one</a> (Accessed on September 4, 2024)</p></li></ol>

This article explores the role of biocompatible inks in bioelectronics, particularly within Direct Ink Writing (DIW) systems and forecasts future trends and challenges in on-body and in-body bioelectronic technologies over the next decade.

The Intersection of Biology and Technology: Exploring the Future of Bioelectronics

<h3 id="isPasted">Understand the Future of Metal 3D Printing</h3><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730910790125-Mitsubishi+Chemical+Group++Growth+Garage++Open+Innovation+Program+%289%29.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h4>Why Read This Report?</h4><p>The 3D printing industry is evolving quickly and staying updated on cutting-edge manufacturing methods is key. This report not only covers the technical processes behind metal laser powder bed fusion, directed energy deposition, metal extrusion, and binder jetting but also delves into:</p><ul><li><strong>Materials &amp; Post-Processing</strong> – Understand the materials powering metal AM and essential post-processing steps for quality assurance.</li><li><strong>Industry Applications</strong> – See how metal 3D printing is reshaping aerospace, medical, and automotive industries with specific use cases.</li><li><strong>Future Trends</strong> – Get a glimpse of emerging trends, sustainability practices, and the exciting potential of metal AM through case studies and industry insights.&nbsp;</li></ul><p>Whether you're new to metal AM or looking to expand your knowledge, this report offers valuable insights to help you make informed decisions and stay ahead.</p><h4>Get Inspired by Real-World Successes</h4><p>Discover how leading companies are using metal 3D printing to overcome complex manufacturing challenges, streamline production, and unlock new possibilities.</p><h4>Download Now</h4><p><br></p>

<h3 id="isPasted">Understand the Future of Metal 3D Printing</h3><p>The <strong>Metal 3D Printing Technology Report</strong> is your essential guide to the latest advances, applications, and real-world insights into additive manufacturing with metal. Packed with detailed case studies, &nbsp;practical information, and interviews with industry leaders, this report reveals how metal 3D printing is transforming industries and pushing the boundaries of manufacturing.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730910790125-Mitsubishi+Chemical+Group++Growth+Garage++Open+Innovation+Program+%289%29.png" style="width: 100%px;" class="fr-fic fr-dib"></p><h4><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width:100%;max-width:100%;height:950px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></h4><h2>Why Read This Report?</h2><p>The 3D printing industry is evolving quickly and staying updated on cutting-edge manufacturing methods is key. This report not only covers the technical processes behind metal laser powder bed fusion, directed energy deposition, metal extrusion, and binder jetting but also delves into:</p><ul><li><strong>Materials &amp; Post-Processing</strong> – Understand the materials powering metal AM and essential post-processing steps for quality assurance.</li><li><strong>Industry Applications</strong> – See how metal 3D printing is reshaping aerospace, medical, and automotive industries with specific use cases.</li><li><strong>Future Trends</strong> – Get a glimpse of emerging trends, sustainability practices, and the exciting potential of metal AM through case studies and industry insights.&nbsp;</li></ul><p>Whether you're new to metal AM or looking to expand your knowledge, this report offers valuable insights to help you make informed decisions and stay ahead.</p><h4>Get Inspired by Real-World Successes</h4><p>Discover how leading companies are using metal 3D printing to overcome complex manufacturing challenges, streamline production, and unlock new possibilities.</p><hr><h2>Report introduction</h2><p dir="ltr">Metal 3D printing, also known as metal additive manufacturing (AM), is a production technology whose origins date back just three decades to 1994, when German company EOS GmbH launched a system based on its Direct Metal Laser Sintering (DMLS) technology<sup>1</sup>. Despite this short history (particularly compared to metal casting, which dates back thousands of years), metal AM has progressed significantly since its earliest iteration, with various new types of processes being developed, new materials and applications being validated, and consistent market growth. This growth—and the continued proliferation of metal AM technologies—is evident by simply looking at the number of metal AM systems sold from year to year. From 2022 to 2023, for instance, the shipment of metal AM systems grew by 24.4% (from 3,049 systems in 2022 to 3,793 systems in 2023). To put it into perspective, just ten years ago, the number of metal AM systems sold was barely over 500<sup>2</sup>.</p><p dir="ltr">Amongst 3D printing users more generally, there has also been an increase in metal AM adoption, from 39% in 2019 to over 90% in 2023<sup>3</sup>. This indicates how the technology has matured and offers a viable production method for a growing number of prototyping and production applications that benefit from the technology’s propensity for complex designs and small-volume production. While challenges to the broader adoption and implementation of metal AM still exist, efforts are being made across the industry to address these barriers through hardware, software, and materials advances as well as industry-wide cooperations.&nbsp;</p><p dir="ltr">This report delves into the metal 3D printing market, whose estimated global value in 2023 was as high as $7.73 billion<sup>4</sup>, for a full spectrum view of the state of the industry. This report includes insights into the leading metal 3D printing processes available on the market today as well as metal AM materials. The report also highlights other vital steps in the AM process chain, including design and post-processing. The fifth chapter of the report covers metal 3D printing applications, with a focus on the three leading adopter industries: aerospace, medical, and automotive. The next two chapters comprise an analysis of the challenges and limitations facing the metal AM industry as well as the key trends that indicate where the future of the industry is headed. The report’s final chapter presents exclusive insights from three companies active in the metal AM space: manufacturing service Xometry, FFF 3D printing company UltiMaker, and software specialist Aibuild.</p><h3>Tess Boissonneault</h3><p>Report Editor-in-Chief</p><p>Read an excerpt from <a href="https://www.wevolver.com/draft/article/chapter-1-core-metal-3d-printing-technologies">chapter 1</a> here or downlowd the full report below.</p><p><br></p><p><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe id="JotFormIFrame-243032488553458" title="Metal 3D Printing Report" allowtransparency="true" src="https://form.jotform.com/243032488553458" frameborder="0" style="min-width:100%;max-width:100%;height:950px;border:none;" scrolling="no" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span> </iframe></span></p><h2>Acknowledgements:</h2><p>Thank you to contributing author Benedict O’Neill.&nbsp;</p><p>Huge gratitude to the experts at UltiMkaer, Xometry and AIBuild with who we consulted with on the texts.&nbsp;</p><h2>References:</h2><p dir="ltr" id="isPasted">1. Singh A, Singh H. Metal additive manufacturing: from history to applications. InInnovations in Additive Manufacturing 2022 Jan 31 (pp. 3-32). Cham: Springer International Publishing.&nbsp;</p><p dir="ltr" id="isPasted">2. Wohlers Report 2024 [Internet]. Wohlers Associates; 2024. Available from: <a href="https://wohlersassociates.com/product/wr2024/">https://wohlersassociates.com/product/wr2024/</a>&nbsp;</p><p dir="ltr" id="isPasted">3. Jabil Unveils Findings of Global Survey on 3D Printing Technology Trends [Internet]. Jabil; July 27, 2023. Available from: <a href="https://investors.jabil.com/news/news-details/2023/Jabil-Unveils-Findings-of-Global-Survey-on-3D-Printing-Technology-Trends/default.aspx">https://investors.jabil.com/news/news-details/2023/Jabil-Unveils-Findings-of-Global-Survey-on-3D-Printing-Technology-Trends/default.aspx</a>&nbsp;</p><p>4. Metal 3D Printing Market Size, Share &amp; Trends Analysis Report By Technology, By Software, By Component (Hardware, Software, and Services), By Application, By Printing Type, By Vertical, By Region, And Segment Forecasts, 2024 - 2030 [Internet]. Grandview Research; 2024. Available from: https://www.grandviewresearch.com/industry-analysis/metal-3d-printing-market</p>

Introduction

An engineer’s guide to understanding the state
of the art in metal 3D Printing

Metal 3D Printing Technology Report

<p data-pm-slice="1 1 []" id="isPasted">Metal 3D printing, once the domain of advanced industrial applications, is now making its way into universities and research institutions, offering students hands-on experience with cutting-edge manufacturing technologies. Here’s how metal 3D printing is transforming education and why it’s an essential tool for preparing the next generation of engineers and designers.</p><p><strong>Metal 3D Printing in Universities: Building Practical Skills and Industry Connections</strong></p><ol><li data-list-indent="1" data-list-type="bulleted"><p><strong>Hands-On Learning with Real-World Applications</strong>: Integrating metal 3D printers into university curricula offers students invaluable practical experience with advanced manufacturing technologies. This hands-on approach not only helps students develop essential engineering and design skills but also enables them to work on real-world projects in collaboration with industry partners. These collaborations provide students with opportunities to apply theoretical knowledge in practical settings, bridging the gap between academia and industry and preparing them for the professional challenges they will encounter after graduation.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Fostering Innovation through Industry Collaboration</strong>: By working on real projects with companies, students gain direct exposure to the latest industry practices and technologies. This experience is critical for understanding the practical applications of metal 3D printing and helps to cultivate innovative thinking. At the same time, companies benefit from the fresh insights and creative solutions that students bring to the table, making these partnerships mutually beneficial and driving innovation across the board.</p></li></ol><p><br></p><p><strong>Safety First: The Importance of a Safe and User-Friendly System</strong></p><p><strong>Minimized Powder Contact</strong>: Safety is a critical consideration when introducing metal 3D printing into educational settings. Systems like the <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">One Click Metal printer</a> are designed with safety in mind, featuring a cartridge system that minimizes direct contact with metal powders. This ensures that students can focus on learning without the risks associated with powder handling.</p><p><br></p><p><strong>Research and Advanced Learning</strong></p><p><strong>Versatile and Research-Ready</strong>: The One Click Metal <a href="https://oneclickmetal.com/lab-module/" target="_blank" rel="noopener noreferrer">Lab Module</a> is designed specifically for research purposes, making it an excellent addition to university labs. This build module allows for printing with a variety of materials in small, precise amounts, enabling detailed experimentation and material studies. The Lab Module’s ability to work with different materials in small quantities makes it perfect for research projects that require a high level of precision and material flexibility. Students and researchers can experiment with new materials, optimize printing parameters, and push the boundaries of what’s possible with metal 3D printing.</p><p><br></p><p><strong>Conclusion: A Tool for the Future of Education</strong></p><p>Metal 3D printing is more than just a manufacturing technology—it’s a tool for education and innovation. By bringing metal 3D printers into universities, students are given the opportunity to develop practical skills, engage in real-world projects, and prepare for successful careers in engineering and design. With safe, user-friendly systems, educational institutions can offer a learning experience that equips students with the knowledge and skills they need to lead in the industries of tomorrow.</p>

Metal 3D printing at Trier University of Applied Sciences

As technology continues to advance, the educational sector is evolving to ensure that students are equipped with the skills and knowledge necessary for the future.

The Role of Metal 3D Printing in Education

<p dir="ltr" id="isPasted">The 3D printing industry has grown rapidly in recent years, with its recorded market size of $20.68 billion in 2023 to $24.61 billion in 2024. This growth is expected to continue as the projections indicate that by 2033, the 3D printing market will reach around $117.78 billion with a compound annual growth rate (CAGR) of 19% between 2024 and 2033.&nbsp;1&nbsp;However, this growth can be even more impressive if challenges related to time-consuming and labor-intensive post-processing tasks are rectified. The post-processing tasks, such as cleaning, sanding, and finishing, often consume a considerable portion of the overall production time, impacting efficiency and profitability.</p><p dir="ltr">This challenge has been taken head-on by <a href="https://am-flow.com/about-us/">AM-Flow</a>, a leader in automation technology focused on automating the post-processing workflow, specifically in sorting, to bring scalability to the 3D printing sector. Feeding, identification, sorting, quality control and bagging are all essential yet labor-intensive parts of post-processing, which often leads to production delays and inconsistencies. AM-Flow offers a solution by streamlining the sorting process to improve speed, scalability, and cost-efficiency.&nbsp;This article explores how AM-Flow's post-processing automation solutions are transforming the 3D printing landscape.</p><h1 dir="ltr">Overview of Sorting Post-Processing in 3D Printing</h1><p dir="ltr">A 3D printing workflow starts with the design phase, where a digital model is created using CAD software. This model is then exported in a compatible format, like STL or OBJ, and imported into slicing software, where the model is converted into layers and tool paths, with parameters like print speed, temperature, and material type being defined. The slicing software generates a G-code file that guides the printer during production. After that, the actual printing starts by depositing the material layer by layer to build the 3D object.&nbsp;</p><p dir="ltr">After printing, the part enters the post-processing phase, which may include removing supports, sanding, and polishing to enhance the surface finish. However, particularly the sorting of parts in post-processing, presents several challenges. For instance, in additive manufacturing, once a batch of parts is printed, they require cleaning and sometimes surface treatment or finishing. These parts, produced in large quantities, often vary in shape, size, material, and complexity, which makes manual sorting laborious and error-prone.&nbsp;</p><h1 dir="ltr" id="isPasted">Innovating Automation for Enhanced 3D Printing Post-Processing</h1><p dir="ltr">When production scales up, the manual sorting process becomes unsustainable, leading to higher operational costs and lower productivity. Therefore, manufacturers struggle to meet high demand efficiently without automation while maintaining product quality. In this regard, AM-Flow's multi-faceted solution automates the workflow between several post-printing steps, providing a comprehensive approach to streamlining the sorting process and improving overall efficiency.</p><p dir="ltr">AM-Flow is a cutting-edge automation company that provides solutions for the additive manufacturing industry and has developed a range of innovative technologies designed to optimize the post-processing workflow in response to the unique challenges faced by 3D printing companies. AM-Flow specializes in automating the feeding, identification, sorting, quality control and bagging&nbsp;of 3D printed parts.</p><p dir="ltr">AM-Flow utilizes advanced technologies like computer vision, artificial intelligence, and robotics to provide post-processing solutions. Their complete suite of solutions addresses various stages of the post-processing workflow, from sorting and identifying parts to packaging and transporting them within production environments.&nbsp;</p><p dir="ltr"><span contenteditable="false" draggable="true" class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable"><iframe src="https://www.youtube.com/embed/sGprIKnzL_8?&amp;wmode=opaque&amp;rel=0&amp;enablejsapi=1&amp;origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true" style="width: 640px; height: 440px;"><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span><span class="fr-mk" style="display: none;">&nbsp;</span></iframe></span></p><h1 dir="ltr">Step-by-Step: How Automation Technologies Work in 3D Printing Post-Processing</h1><h2 dir="ltr">1. &nbsp; &nbsp;System Installation and Integration</h2><p dir="ltr">AM-Logic serves as the base of AM-Flow's post-processing automation, integrating with the client's existing Manufacturing Execution System (MES), which ensures a smooth flow of information and enables the system to stay updated with the latest orders, parts to be printed, and relevant specifications. This digital connection enables the automated system to receive data on builds and production requirements, significantly reducing manual intervention and ensuring that post-processing aligns perfectly with production goals.</p><h2 dir="ltr">2. &nbsp; &nbsp;Import and Nesting of Builds</h2><p dir="ltr">As parts and builds are nested and saved in the MES, they are automatically imported into the AM-Flow system, which allows the computer vision component of the system, known as <a href="https://am-flow.com/products/am-vision/">AM-Vision</a>, to scan, and identify parts based on specific parameters attached to each part and relay that information to the AM-Sort. AM-Vision uses sophisticated algorithms to analyze images of 3D-printed parts and extract relevant information such as geometry, size, and color. The system can accurately identify individual parts, even in complex mixtures, ensuring that they are sorted correctly and efficiently.&nbsp;</p><h2 dir="ltr">3. &nbsp; &nbsp;Operator Sorting Process</h2><p dir="ltr">After a mandatory cleaning or blasting process which is typically required for powder bed technologies, the operator retrieves the parts ready to be sorted. The operator selects the relevant build (e.g., DD-MM-YYYY _ PRINTER1) and sets sorting criteria. The AM-Flow system provides a user-friendly interface that makes it easy for operators to input data and monitor the sorting process. Operators can select different sorting criteria based on the specific requirements of the production process, which ensures that the system is tailored to the needs of the individual manufacturing facility.</p><p dir="ltr">In addition to improving the sorting process, AM-Flow’s automation technology helps reduce constraints in build nesting, which can often limit the printer’s efficiency. By optimizing material usage and minimizing the need for segregating orders based on materials or processes, AM-Flow enables manufacturers to pack builds more effectively, reducing manual sorting complexity and operational delays. For more details on how this impacts overall productivity, visit <a href="https://am-flow.com/about-us/" target="_blank" rel="noopener noreferrer">AM-Flow’s website</a>.<a href="https://am-flow.com/about-us/"></a></p><h2 dir="ltr">4. &nbsp; &nbsp;Automating Identification in Post-Processing</h2><p dir="ltr">AM-Vision represents a major leap in post-processing efficiency as this system can accurately identify 3D-printed parts based on their geometric features, such as shape, size, and color, using advanced computer vision and AI-driven image recognition algorithms. For instance, AM-Vision has the capability of processing up to 5760 parts in 8 hours, which significantly reduces the time and labor required for part identification and classification.</p><p dir="ltr">After identifying the part and checking the sorting criteria, AM-Vision passes the sorting information to AM-Sort, ensuring the correct flipper arm opens and pushes the part into its designated bin for that part or group of parts. This automation step eliminates the need for operator involvement at this stage. The adaptability of AM-Vision ensures it can integrate into any post-processing workflow, accommodating various materials, technologies, and part specifications with minimal disruptions.</p><h2 dir="ltr">5. &nbsp; &nbsp;Sorting and Grouping Parts</h2><p dir="ltr"><a href="https://am-flow.com/products/am-sort/">AM-Sort</a> is another key component of AM-Flow's automation that represents the ultimate automated sorting solution. AM-Sort receives instructions from AM-Vision on which flipper arm to activate for the scanned and identified parts. It consists of a single conveyor belt that begins at the entrance of AM-Vision and is solely responsible for directing parts to their designated bins. AM-Vision not only determines the correct path for each part, but also provides its precise position on the conveyor, ensuring the flippers open and close at the right moment.</p><p dir="ltr">After sorting, the parts re-enter the system as post-processed items rather than by their initial build characteristics. This process repeats until each part reaches its final stage of post-processing, at which point they are ready for bagging and labeling through the <a href="https://am-flow.com/products/am-bagging/">AM-Bagging</a> module, which seamlessly integrates with AM-Sort exits.&nbsp;</p><h1 dir="ltr">Enhancing Efficiency and Scalability in Post-Processing Workflows</h1><p dir="ltr">Post-processing automation is becoming a critical factor in maximizing the efficiency and scalability of 3D printing operations. Addressing the labor-intensive and time-consuming nature of traditional post-processing is imperative for manufacturers to remain competitive. In this regard, AM-Flow has transformed post-processing by offering innovative solutions that automate key steps such as sorting, identification, and transportation of 3D-printed parts. AM-Flow enables manufacturers to streamline their post-processing workflows, reduce costs, and improve scalability by utilizing AM-Flow's advanced technologies like AI-driven computer vision, robotics, and seamless system integration.</p><h1 dir="ltr">Optimize Your 3D Printing Operations</h1><p dir="ltr">As the additive manufacturing industry advances further, 3D printing companies should consider <a href="https://am-flow.com/solutions/" target="_blank" rel="noopener noreferrer">AM-Flow's solutions</a> for streamlining their post-processing in order to stay competitive in the evolving additive manufacturing landscape. Explore the <a href="https://am-flow.com/solutions/" target="_blank" rel="noopener noreferrer">AM-flow website</a> or <a href="https://am-flow.com/contact/">book a meeting with the team</a> to find out how their solutions can help you optimize production, minimize delays, and enhance overall operational efficiency.</p><h1 dir="ltr">References</h1><ol><li dir="ltr"><p dir="ltr">3D Printing Market Size, Share, and Trends 2024 to 2033. [Online] Precedence Research. Available at: <a href="https://www.precedenceresearch.com/3d-printing-market">https://www.precedenceresearch.com/3d-printing-market</a> (Accessed on October 7, 2024) AM-Flow. Available at: &nbsp;<a href="https://am-flow.com/about-us/">https://am-flow.com/about-us/</a></p></li></ol>

Automated solutions in post-processing address the challenges of 3D printing workflows, allowing for more precise sorting, efficient handling of diverse parts, and rapid iteration without manual bottlenecks.

The Future of 3D Printing Lies in Automated Post-Processing: Here's Why

<p data-pm-slice="1 1 []" id="isPasted">When a leading INDEX multi-spindle machine encountered significant challenges with chip removal, tool life, and coolant management, the introduction of a custom 3D-printed coolant ring provided an innovative solution that dramatically improved performance.</p><p data-pm-slice="1 1 []" id="isPasted"><strong>The Challenge: Poor Chip Removal and Inconsistent Coolant Coverage</strong></p><p>The machining process on an <a href="https://www.index-group.com/en_us/company/about-us/index-corporation" target="_blank" rel="noopener noreferrer">INDEX</a> multi-spindle machine was being compromised by poor chip removal, leading to shortened tool life and heightened fire risks. These issues stemmed from inconsistent coolant coverage, which was exacerbated by the machine’s compact design. Standard coolant nozzles were difficult to install due to limited space, and accessing tools with the probe was challenging. Moreover, operators were required to manually remove coolant lines during each tool change, introducing delays and variability that depended on the skill and experience of the operator.</p><p>This situation not only reduced the efficiency of the machining process but also posed safety risks, making it clear that a more reliable and effective solution was needed.</p><p><br></p><p><strong>The Solution: A Custom Metal 3D-Printed Coolant Ring</strong></p><p>To address these challenges, the engineering team designed a custom metal 3D-printed coolant ring with internal channels optimized for efficient coolant flow. <a href="https://oneclickmetal.com/boldseries/" target="_blank" rel="noopener noreferrer">Metal 3D printing</a> was chosen for its ability to produce highly customized parts that precisely meet the stringent specifications required for this application.</p><p>The coolant ring was engineered to withstand coolant pressures of up to 40 bar, resist oil, and ensure non-flammability. It was fabricated from non-toxic, non-corrosive materials to maintain an absence of contaminants throughout its life cycle. The design also ensured that the coolant ring was easy to install, space-saving, and allowed for easy probe accessibility.</p><p>The coolant oil is directed through an adapter block into the inlet of the coolant ring. Inside the ring, the oil flows uniformly, being dispensed evenly from three openings to ensure precise delivery to the tool's tip. This design not only improved coolant coverage but also enhanced process stability, as the coolant ring could be removed and reattached independently of the operator, significantly reducing the time required for tool changes.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730200060177-Coolant+ring.jpg" style="width: 487px;" class="fr-fic fr-dib"></p><p><strong>The Benefits: Enhanced Efficiency, Safety, and Tool Life</strong></p><p>The introduction of the custom 3D-printed coolant ring brought numerous benefits to the machining process:</p><ol><li data-list-indent="1" data-list-type="bulleted"><p><strong>Better Chip Removal</strong>: The optimized design of the coolant ring ensured consistent and effective coolant flow, greatly improving chip removal and reducing the risk of tool damage.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Increased Tool Life by a Factor of 20</strong>: With improved coolant coverage and chip removal, the tool life was extended dramatically, reducing the frequency of tool changes and lowering operating costs.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Improved Process Stability</strong>: The ability to remove and reattach the coolant ring without relying on the operator reduced variability and enhanced overall process stability.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Three Times Faster Tool Change Time</strong>: The streamlined design and ease of reattachment allowed for much quicker tool changes, tripling the speed of this critical process and further enhancing productivity.</p></li><li data-list-indent="1" data-list-type="bulleted"><p><strong>Safer Manufacturing Environment</strong>: The consistent coolant coverage and improved chip removal minimized the risk of fire, contributing to a safer working environment.</p></li></ol><p><strong>Conclusion: A Custom Solution for Optimized Performance</strong></p><p>The integration of a custom metal 3D-printed coolant ring into the INDEX multi-spindle machine represents a significant advancement in machining efficiency and safety. By leveraging the capabilities of metal 3D printing, the engineering team was able to overcome the limitations of traditional coolant systems, providing a solution that not only met but exceeded the demands of the application. This case study highlights the transformative potential of 3D printing in creating tailored solutions that enhance the performance and reliability of critical manufacturing processes.</p>

In the world of precision machining, efficiency and reliability are paramount. This case study explores the challenge, solution, and benefits of integrating a metal 3D-printed coolant ring into the machining process.

Improving Efficiency with Customized 3D-Printed Coolant Rings

<p id="isPasted">In a previous article, we talked about the benefits of&nbsp;<a href="https://ultimaker.com/learn/benefits-of-3d-printing-in-automated-packaging/">3D printing in automated packing</a> from a high-level overview outlining how the flexibility of additive manufacturing can save costs, simplify material components and improve the end-to-end process.</p><p>More recently we’ve also hosted a webinar on how to&nbsp;<a href="https://ultimaker.com/learn/leverage-3d-printing-for-automated-packaging-with-real-life-applications/">leverage 3D printing for automated packaging with real life applications</a> (we highly recommend you check it out) and based on the interest generated and questions received during the presentation we wanted to provide you with a more comprehensive in-depth view over actual examples where 3D printing has made significant and sustained impact for several of our clients.</p><p>So let’s dive into it!</p><h3>Automated Packaging Systems</h3><p>Leaning into the flexibility aspect previously covered, we want to be clear that 3D printing can be integrated in all types of automated packaging systems such as filling, sealing, labeling and wrapping machines, palletizing systems and many others. Clients such as Heineken, Krones, Ben&amp;Jerry’s, P&amp;G, Schubert, CocaCola, PepsiCo, Lego and Trivium to name a few, have all successfully integrated UltiMaker’s 3D printing solutions in their automated packaging processes and have all been part of our customer success stories.</p><p>Below we’ll cover different wear parts, starwheels/sprockets, format specific tools such as infeed screws, LOTO/safety tools and ergonomic enhancements that have been made possible by 3D printing.</p><p>Starwheel, infeed starwheel and sprockets:</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169955965-UltiMaker-Packaging-starwheel-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Let’s start with one of the backbones of any production line, the starwheel used to drive conveyor/packaging lines, which was also featured on our&nbsp;<a href="https://ultimaker.com/learn/krones-optimized-3d-printed-parts-spares-for-customers-anywhere/">Krones success story</a>. The key requirements for a starwheel is for the part to have a high dimensional stability and high wear and tear resistance.</p><p>When compared to traditional starwheels made out of POM, the 3D printed variant is cheaper (example part shown above was printed out of PET CF for around 44 €) and able to be optimized for each individual use case, which went coupled with the fact that these parts need to be replaced periodically, the fact that you can set the part to print at the end of your work schedule and have it ready the next day is a benefit that we simply don’t see with traditional sourcing or manufacturing methods.</p><p>We also want to point out one of the cooler features that can be leveraged with 3D printing that is unavailable for other manufacturing processes (such as milling): dual material extrusion. The ability to print 2 different materials into one part, for example in an infeed starwheel, where the bulk of the part can be made out of a stiff high resistant material, and the outer wall can be printed out of a low friction material enables our clients to save up on material costs without compromising part integrity or functionality.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169970195-UltiMaker-Packaging-infeed-starwheel-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">Another benefit is the ability to optimize designs to use less material when printing, while part of this process is already accounted for when considering infill percentage (infill being the amount of material used to fill the internal volume of a part) the design process allows our clients to optimize the part further.</p><p>One relevant example can be seen in the sprocket design below where the inside was printed out of a rigid technical material and a wear resistant material on the outside which allowed for reduced printing times while retaining part functionality and durability.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169982608-UltiMaker-Packaging-sprocket-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Inverter tunnels</h3><p>Product orientation changes during the packaging process, for example expiration dates on ice cream cups are typically printed on the bottom which is obviously not the natural orientation of the product during the filling process. As their name indicates, inverter tunnels are used to flip or invert products as they pass through the production line, designed to rotate items 180 degrees allowing them to be positioned correctly for the next step in packaging process (typically used for labeling, sealing or further processing).</p><p>Traditionally, most inverter tunnels are made out by milling large blocks of POM material which is both wasteful and time consuming, but with 3D printing inverter tunnels can be optimized to be printed without supports as a single funnel system as seen below (for reference the part in the image cost €15 to print out of UltiMaker PLA Blue).</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730169996187-UltiMaker-Packaging-inverter-tunnel-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">In case there are any concerns regarding the layer lines, please note that they do not cause any snagging or reduction in performance when compared to a traditional inverter. We’ll touch upon materials a bit later in the article but suffice to say that there is a plethora of low friction materials available that practically enable the item inside the tunnel to slide by itself.</p><p>Inverter tunnels are also a prime example where the complex geometries of some products would make the part manufacturing through milling impossible due to the limitation in producing curved, non-uniform pathways. You can check out&nbsp;<a href="https://www.linkedin.com/posts/jeremy-evers-18a79bb1_3dprinting-additivemanufacturing-ultimaker-activity-7236632063146143744-upOx">this cool short presentation</a> made by our Senior Application Engineer, Jeremy Evers.</p><h3>Guide Rails</h3><p>One of the easiest things to optimize in a production line are product guide rails, whether it’s over longer distances or short corners; the flexibility that comes with 3D printing allows for the implementation of durable guide rails with several benefits over traditional options.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170011020-UltiMaker-Packaging-guide-rails-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">In the above example the guide rails were created for a bottle packaging line and printed in two materials, the tougher more rigid PET CF Gray for the structure and a more wear resistant low friction material on the inside as it would come in contact with the bottles. The best part in this use case is that when the wear strips need to be replaced you would only need to reprint them and slide them into place on the existing structure (for reference the part shown cost €25 to print with the cost of the wear strips alone being around €7-8).</p><h3>Infeed scroll/timing screws</h3><p>With previous parts we’ve touched upon the cost savings through reduced material use in manufacturing, faster lead times and design optimizations but what about instances where you are not able to source components for existing machinery? This was one of the challenges that our client Trivium faced when they were no longer able to source infeed worms to push aluminum cans forward on the production/packaging line.</p><p>With UltiMaker they were able to quickly iterate and design their own infeed worms, 3D print them and ultimately print their optimized design using carbon reinforced nylon and keep their production rolling. For more information on how Trivium used 3D Printing to help replace parts in their automated packaging lines, you can also <a href="https://ultimaker.com/learn/trivium-3d-printing-replacement-parts-for-automated-packaging-lines/">check out this article</a>.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170025902-UltiMaker-Packaging-indeed-scroll-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">The ability to quickly design replacement parts for existing machines without compromising on part functionality or durability and have production back up and running within days without the need to externally source parts and get bogged down with delivery times is a critical benefit that becomes even more important when talking about remote locations such as Africa or South America. The best thing about UltiMaker’s 3D printing solution is that clients can send the digital part files to any connected location and have the part printed locally reducing the need of skilled onsite labor.</p><h3>LOTO safety tool</h3><p>At a glance the ability to optimize safety during maintenance with 3D printing by always having an affordable and adaptable safety LOTO (“lockout-tagout”) procedure for any valve, switch, latch, connector for any type of machine in bright visual colors cannot be overstated.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170039983-UltiMaker-Packaging-LOTO-safety-tool-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><p id="isPasted">For this application, it’s the flexibility that offers the biggest advantage as any potential risks that are identified can be resolved onsite, for example a chain cover that would normally require a lengthy delivery time, could easily be designed and printed onsite within hours optimizing worker’s safety.</p><h3>Wear parts</h3><p>From bottleneck grippers to can pushers, pack spinners to transition combs, 3D printing allows quick on-demand part replacement without taking up valuable warehouse space which as mentioned earlier is especially valuable when talking about remote plant locations.</p><p>The intrinsic value of additive manufacturing in creating complex custom geometries means that not only can you replace individual parts but also complete assemblies creating a single, stronger part that is less likely to break or leak. One especially useful example we’ve seen is for top-loading machine (TLM) suctions assemblies.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730170057682-UltiMaker-Packaging-wear-parts-wide.jpg" style="width: 100%px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Materials</h3><p>One of the most common concerns when it comes to 3D Printing materials is whether it can hold up to the same standard as metal milled parts and we want to be clear, you can replace metal with plastic. Working with hundreds of companies we’ve noticed that applications made of metal are often overkill for a part’s mechanical needs, and because of the mentioned benefit of 3D printing technology being able to create geometries that are not achievable through machined metal, clients are able to create lightweight parts using a wide range of available materials that are fit for purpose.</p><p>That being said, when thinking about what material to use, you have to know the requirements:</p><ul><li>Functional: e.g. strength, flexibility, durability, rigidity</li><li>Environmental exposure: e.g. temperature, humidity, chemicals</li><li>Weight and size constraints</li><li>Industry standards, material certifications, safety or regulatory material constraints. .</li><li>Aesthetic or surface finish: e.g. color, texture</li><li>How long should the material last under normal usage conditions.</li></ul><p>While a full list of available materials can be referenced on our&nbsp;<a href="https://marketplace.ultimaker.com/app/cura/materials">UltiMaker Marketplace</a> where we’re confident that you’ll find everything you need to best suit your needs, from FDA and EU Food Contact certified materials, medical grade polymers to PPS CF steel and aluminum replacement alternatives, we also wanted to present some of the recommended materials we’ve seen used by our clients in the food and beverage industry:</p><ul><li><a href="https://marketplace.ultimaker.com/app/cura/materials/Nicolas_Tokotuu/Polymaker_PolyMide_CoPA_2019">Polymaker CoPA</a> - Low friction coefficient, impact resistant</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/NE/IGUS_iglidurI150">Igus iglidur i150</a> - EU 10/2011 certified for food contact, self-lubricating, easy to print</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/NE/IGUS_iglidurI180">Igus iglidur i180</a> - High load and wear resistance</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/thiagomedeiros/LUVOCOM3F50588">Lehvoss 50588</a> - Magnetically detectable, FDA food safe certified, available in blue</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/FVI/kimya_PETG">Kimya PETG-S</a> - Easy to print, FDA food contact certified, available in blue</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/UltimakerPPSCF">UltiMaker PPS CF</a> - Easy to print, extreme stiffness, high temperature resistance(HDT B of over 230℃ after printing)</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/UltimakerPackages/ultimaker_pet_cf">UltiMaker PET CF</a> - Easy to print, dimensional stability, high toughness, available in blue</li><li><a href="https://marketplace.ultimaker.com/app/cura/materials/NE/IGUS_iglidurI190">Igus Iglidur i190</a> - High temperature resistance, wear resistance</li></ul><h3>Change the game</h3><p>With overall costs increasing in the manufacturing and packaging industry and supply chain instability further contributing to volatile market dynamics we know that 3D printing can help you not just adapt, but change the game.</p><p>All of our clients so far have benefitted from safer working environments, decreased lead-times and costs, improved warehousing and stock management, increased factory line uptime, faster time to market and increased overall equipment efficiency.</p>

Leaning into the flexibility aspect previously covered, we want to be clear that 3D printing can be integrated in all types of automated packaging systems such as filling, sealing, labeling and wrapping machines, palletizing systems and many others.

Applications of 3D Printing in Automated Packaging

<p id="isPasted">Injection molding vs. 3D printing doesn’t have to be an either/or proposition. Some projects use both processes during a product’s lifecycle. Traditionally, 3D printing has been used for prototyping and injection molding has been used for production. Additive manufacturing has advanced, however, and 3D printed parts aren’t limited to prototypes anymore.</p><p>Today, there are 3D printing technologies that can create production-quality components – and in the volumes you may require. These technologies include <a href="https://bmf3d.com/" target="_blank" rel="noopener">Projection Micro Stereolithography (PµSL)</a> from Boston Micro Fabrication (BMF), a form of microscale 3D printing that supports the use of plastics, metal-plated plastics, ceramics, hydrogels, and composites resins.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085049022-Metal-plated-turbine.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Metal-plated 3D printed plastic parts</span></span></span></p><section id="isPasted"><p>3D printing has many advantages, but there’s often a part volume – a crossover point – where injection molding is used. With plastic injection molding, tooling that costs tens or even hundreds of thousands of dollars can be amortized across these high production volumes. Quantity is just one consideration, however, so consider these ten factors when comparing injection molding vs. 3D printing for your project.</p><ol><li>Lead Times</li><li>Setup Costs</li><li>Volumes</li><li>Materials</li><li>Part Size</li><li>Part Tolerances</li><li>Part Strength</li><li>Design Maturity</li><li>Design Complexity</li><li>Surface Finish</li></ol><p>The following sections explain.</p></section><section><h3><strong>#1 Lead Times</strong></h3><p>The steel or aluminum molds that are used with injection molding can take weeks or months to machine. The injection molder then sends a customer part samples for functional testing and dimensional measurements. If the initial samples aren’t suitable, the mold maker may have to adjust the tool, which extends project timetables.</p><p>3D printing has shorter lead times. Unlike injection molding, there’s isn’t a metal tool that needs to be CNC or EDM machined. Customers still need part samples, but there isn’t a mold to modify if changes are required – and the settings on a 3D printer can be adjusted. Using 3D printing, it’s even possible to produce low-volume injection molds. &nbsp;For high volumes in a single run, however, injection molding is faster.</p></section><section><h3><strong>#2 Setup Costs</strong></h3><p>Most injection molding costs are associated with the tool. Steel costs more than aluminum, and both metals cost more than the 3D plastics that are used to build some low-volume molds. Production molds cost more than prototype molds as well. With injection molding, tooling costs also vary with mold size and complexity. 3D printing eliminates these costs and the variability that comes with them.</p></section><section><h3><strong>#3 Volumes</strong></h3><p>There are four volumes of parts to consider when comparing injection molding vs. 3D printing: initial order quantity, annual order quantity, total quantity, and crossover volume. Standard parts have a crossover volume in the low thousands. Small, high-precision parts have crossover volumes in the tens of thousands, and that’s part of the reason <a href="https://bmf3d.com/ultra-high-resolution-3d-printers/">BMF’s microscale 3D printers</a> are used instead of micro injection molding.</p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085117712-1730085117712.png" class="fr-fic fr-dib"></p><section id="isPasted"><h3><strong>#4 Materials</strong></h3><p>Injection molding and 3D printing support many of the same materials. Examples include ABS, acetal, acrylic, PEEK, PEI, polycarbonate, polyethylene, and PTFE. The end-use properties of injection molded and 3D printed materials aren’t the same, however, and injection molding supports some materials that 3D printing does not, and vice versa. With BMF’s open material system, designers can print with the materials of their choice (including non-plastics) or with BMF’s own specially formulated polymers.</p></section><section><h3><strong>#5 Part Size</strong></h3><p>Micro injection molding can produce small parts, but with high tooling costs and practical limitations such as the size of the mold, the capabilities of the machine, and the part’s minimum wall thickness. Most 3D printers can’t produce microscale components, but PµSL technology can print parts that are <a href="https://www.zdnet.com/article/exclusive-zdnet-interview-bmf-ceo-john-kawola-on-3d-printing-parts-smaller-than-a-human-hair/">smaller than a human hair</a>, which is roughly 70 microns across. PµSL doesn’t just rival precision injection molding in terms of size, however. This form of 3D printing can also achieve extremely tight tolerances.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085142908-MicroScrew4-scaled.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner">Micro Nut and Bolt with M0.3 Threads</span></span></span></p><section id="isPasted"><h3><strong>#6 Part Tolerances</strong></h3><p>For non-critical applications, the <a href="https://www.fictiv.com/articles/injection-molding-tolerances-7-questions-for-designers">tolerance of injection molded parts</a> is usually ± 0.1 mm. For critical components, such as those used in medical applications, ± 0.025 mm is typical. With PµSL technology, manufacturing tolerances are measured in terms of microns instead of millimeters (mm). Given that 1 micron equals 0.001 millimeter, PµSL printing tolerances of ± 10µm ~ ± 25µm are especially tight.</p></section><section><h3><strong>#7 Part Strength</strong></h3><p>Injection molded parts tend to be stronger than 3D printed components. Mainly, that’s because injection molded parts are made are made of a single layer of material. By contrast, 3D printing produces parts layer by layer. Material selection matters, however, and <a href="https://bmf3d.com/blog/injection-molding-vs-3d-printing-ten-considerations/P%C2%B5SL">BMF materials</a> such as RG resin are durable engineering materials that can be used to produce functional end-use parts.</p></section><section><h3><strong>#8 Design Maturity</strong></h3><p>Injection molding is ideal for manufacturing parts with mature designs in high volumes. Once manufacturing begins, however, design changes are impractical. 3D printing readily supports design changes from prototyping through production. In other words, it’s easier to identify and correct problems without scrapping tools or wasting materials, a key consideration for designs that are still maturing.</p></section><section><h3><strong>#9 Design Complexity</strong></h3><p>Compared to injection molding, 3D printing supports greater complexity. From holes in the middle of parts to intricate shapes or spoke-like features, there’s greater design freedom with this form of additive manufacturing. With injection molding, the tool limits part design. For example, parts with right angles may break during ejection and ribs are needed for support.</p><span contenteditable="false" class="fr-img-caption fr-fic fr-dib fr-draggable" style="width: 832px;" draggable="false"><span class="fr-img-wrap"><a href="https://bmf3d.com/wp-content/uploads/2020/06/chip-array-socket2.jpg" target="_blank"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1730085185905-chip-array-socket2.jpg" style="width: 100%px;" class="fr-fic fr-dib"><span class="fr-inner" contenteditable="true">Chip Array Socket with Arrays of 130µm Through Holes</span></a></span></span></section><section id="isPasted"><h3><strong>#10 Surface Finish</strong></h3><p>Finally, comparisons of injection molding vs. 3D printing need to account for surface finish. Generally, 3D printed parts have a rougher surface finish; however, post-build smoothing can be used. Injection molded parts can have a fine finish, but with higher tooling costs. With plastic injection molding, parts are also subject to surface defects such as mold flash.</p></section><section><h2><strong>Comparing Injection Molding vs. 3D Printing</strong></h2><p>Injection molding is ideal for high-volume production and for projects with longer turnaround times. Although it can be used with parts of various sizes, injection molding offers less design freedom. 3D is better for low-volume production runs, designs with frequent changes, and projects with quick turnaround times.</p><p>There are many types of 3D printers, but PµSL technology from Boston Micro Fabrication (BMF) lets designers get prototypes and production-quality parts in small sizes – and without the high costs of micro injection molds.</p></section></section></section>

Injection molding vs. 3D printing doesn’t have to be an either/or proposition. Some projects use both processes during a product’s lifecycle. Traditionally, 3D printing has been used for prototyping and injection molding has been used for production.

Injection Molding vs. 3D Printing: Ten Considerations

What is 3D printing? This article goes over the basics of 3D printing, otherwise known as additive manufacturing, covering its engineering principles and applications.


What is 3D Printing: A Comprehensive Guide to its Engineering Principles and Applications

3D Printing in Medicine-Fri Jun 30 2023 23:59:59 GMT+0200 (Central European Summer Time)

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3d printing

Machines like the Stratasys Fortus 450mc can process high-temp 3D printer filament (credit: Stratasys)

High-temp 3D printer filaments are challenging to print, but they can be used to make vital end-use parts like automotive components.

High-Temp 3D Printer Filament: Material and Hardware Considerations

<p dir="ltr" id="isPasted">Cura tree supports were developed as an alternative to traditional linear supports, enabling geometries with overhangs and steep angles to be 3D printed while achieving greater printing efficiency in terms of print times, material usage, and post-processing. This innovative feature, integrated into the popular Cura slicing software, generates organic, tree-like structures that support certain elements of the 3D print throughout the printing process. In this article, we’ll be covering everything there is to know about Cura tree supports, including how they compare to normal supports, important tree support settings, pros and cons, and when tree supports are most beneficial.</p><h2 dir="ltr">Why do you need support structures?</h2><p dir="ltr">3D printing is unique among manufacturing processes for its ability to produce incredibly complex shapes. Some 3D printing processes, like Fused Deposition Modeling (FDM), however, need a bit of help sometimes to achieve these intricate geometries. Some support, if you will.&nbsp;</p><p dir="ltr">3D printers struggle to print certain features, like overhangs and bridges, because the filament is not adequately reinforced and will succumb to gravity if it is printed in mid-air. That’s where support structures come in. Supports are automatically generated in slicer software programs such as Ultimaker Cura and enable 3D printers to produce parts with features like overhangs and bridges.&nbsp;</p><p dir="ltr">Overhangs are shapes on a <a href="https://www.wevolver.com/article/how-to-make-a-3d-model-for-printing" target="_blank">3D model</a> that jut out at angles of over 45°. Bridges, for their part, are horizontal structures that typically connect two vertical structures. Supports are required to print both these elements so that the filament layers are supported as they are extruded.</p><h2 dir="ltr">Linear supports vs Tree supports</h2><p dir="ltr">There are two main types of support structure: linear supports—also known as normal supports—and tree supports. Linear supports are vertical structures that are printed straight up to support overhangs and bridges. This type of support structure reinforces the entire overhang area and typically consists of a solid shell and infill.[2]</p><p dir="ltr">Tree supports, the subject of this article, are more organic in shape, appearing to grow like tree branches around the 3D model to support overhangs and bridges. One of the defining characteristics of tree supports is that they are printed wider at the base of the model and gradually taper off, providing adequate support while minimizing contact points with the 3D printed part. Tree supports are also hollow, consisting primarily of a shell, which is easy to remove post-printing.&nbsp;</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/cura-support-settings-from-angles-to-z-distance" target="_blank" rel="noopener noreferrer">Cura Support Settings Explained</a></strong></p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 626px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU0NTg0NDgzMzY4LXRyZWVfc3VwcG9ydC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" width="624" height="416" class="fr-fic fr-dii" alt="Ultimaker 3D printer while 3D model"><span class="fr-inner">Unlike linear supports, tree supports wrap around the 3D model, providing support directly where needed.</span></span></span></p><h2 dir="ltr" id="isPasted">How Cura Tree Supports Work</h2><p dir="ltr">In the FDM 3D printing process, a print head extrudes melted thermoplastic filament onto a build platform. As the material is deposited, it begins to solidify. This is repeated layer by layer until an object is built up. In general, supports are needed when the layers of the print do not have enough support from the layers underneath them.&nbsp;</p><p dir="ltr">Cura tree supports differ from regular supports in that they can be printed at different angles, rather than straight up. This enables them to adapt to the printed model’s geometry easily. In other words, they are printed around the model. Cura tree supports ultimately provide direct reinforcement to overhangs using the tips of their branches. This unique approach not only provides adequate support, it also results in fewer contact points between the support structure and the printed model. In the end, this makes the tree supports easier to remove than more traditional linear supports. &nbsp;</p><p dir="ltr">The algorithm that generates tree supports in Cura takes several factors into account when creating the support geometry. Specifically, it considers load distribution (branches are positioned to evenly distribute the weight of the supported structure), self-supporting angles (branches are generated at angles that allow them to be self-supporting), and minimal contact (the algorithm minimizes the contact points for optimal post-processing).</p><p dir="ltr">In Cura slicer software, tree supports can be activated under “Support” settings. There are also several parameters related to tree supports that you can adjust. Below are some of the key Cura tree support settings you should know about[1]:</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>Support Placement</strong></p></td><td><p dir="ltr">With this setting, makers can choose between two options: “touching build plate” and “everywhere”. Touching build plate will generate supports only using the build platform as a base. Everywhere, on the other hand, will generate supports from both the build plate and the 3D model, if needed.</p></td></tr><tr><td><p dir="ltr"><strong>Support overhang angle</strong></p></td><td><p dir="ltr">Setting your support overhang angle will determine at what degree overhangs will require a support structure. All FDM 3D printers can print overhangs of up to 45° without supports, and many can handle angles of up to 50-55°.</p></td></tr><tr><td><p dir="ltr"><strong>Support branch angle</strong></p></td><td><p dir="ltr">This setting is unique to tree supports. The support branch angle controls the maximum angle that tree supports will be printed at. A higher value for the support branch angle will result in more freedom for branches to be printed around the model (this means fewer contact points). That said, increasing the support branch angle too much can lead to less supportive branches. A lower support branch angle will result in more vertical branches that are more stable.</p></td></tr><tr><td><p dir="ltr"><strong>Support branch distance</strong></p></td><td><p dir="ltr">This parameter determines how far the top of the support branches will be to the edge of the overhang. A lower value for branch distance will result in more contact points, which will provide greater reinforcement and increase the quality of the overhang. However, a smaller branch distance can also make the tree support branches harder to remove.</p></td></tr><tr><td><p dir="ltr"><strong>Support branch diameter</strong></p></td><td><p dir="ltr">This setting controls the minimum width of the branch. In other words, how small the branch diameter will be at its thinnest point. A smaller branch diameter will reduce the amount of material usage, but a wider branch diameter will provide greater stability.</p></td></tr><tr><td><p dir="ltr"><strong>Collision resolution</strong></p></td><td><p dir="ltr">This <a href="https://www.wevolver.com/article/best-ender-3-pro-cura-settings-temperature-speed-retraction-more" target="_blank">slicer setting</a> for tree supports ensures that the supports don’t intersect with the 3D model when they are generated. 0.2 mm is the default collision resolution setting in Cura. Increasing the value can lead to faster printing times, but lower quality tree supports.</p></td></tr></tbody></table></div><h2 dir="ltr">The Pros of Cura Tree Supports</h2><p dir="ltr">Cura tree supports have several benefits, which have made them increasingly popular amongst makers and professional 3D printing users. Let’s take a look at some of the main benefits tree supports offer.</p><h3 dir="ltr">Less material waste</h3><p dir="ltr">Open source Cura software developers first came up with tree supports as a way to reduce the amount of material waste generated by supports. They were successful in this effort: tree supports use significantly less material than standard supports because they are almost entirely hollow and because they taper in width. This helps to reduce material waste and material costs.&nbsp;</p><h3 dir="ltr">Faster printing time</h3><p dir="ltr">As an added bonus of using less material, tree supports are also faster to print than conventional support structures. Cura software will tell you how much material supports will use and how long a print will take, so you can directly compare standard and tree supports for a given print job. You can also compare the material usage in the same way.</p><h3 dir="ltr">Smoother surface finish</h3><p dir="ltr">Another reason to use tree supports is that they can improve the surface finish quality of 3D prints compared to traditional supports. This benefit is owed to the simple fact that tree supports are designed to minimize contact points with the 3D model. In some cases, the only touch points between the tree supports and the 3D printed object will be the tips of the branches that support the overhangs. Tree supports therefore require minimal post-processing and shouldn’t affect the quality of intricate or finely detailed 3D prints.</p><h3 dir="ltr">Easy support removal</h3><p dir="ltr">Easy support removal is another consequence of having minimal contact points between the tree supports and the 3D printed model. Normal supports can sometimes bond to the 3D printed model making removal challenging, even requiring tools like pliers or cutters to take them off. Tree supports on the other hand consist of a shell around the print with minimal contact points. In most cases, this means they can be peeled off the final print by hand without significant risk of damage.</p><p><strong>Recommended reading:<a href="https://www.wevolver.com/article/improving-your-3d-printing-success-rate-with-ultimaker-cura" target="_blank">&nbsp;Improving your 3D printing success rate with Ultimaker Cura</a></strong></p><p dir="ltr"><strong><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU0NTg0NDM0ODI5LXRyZWUtc3VwcG9ydC1leGFtcGxlLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="Cura 3D model with tree supports"><span class="fr-inner" spellcheck="false">Tree supports are generally easier to remove than linear supports because they have fewer contact points. Image Credits:&nbsp;<a href="https://support.ultimaker.com/hc/en-us/articles/360012612779-Support-settings" rel="noopener noreferrer" target="_blank">Ultimaker</a></span></span></span></strong></p><h2 dir="ltr" id="isPasted">The Cons of Cura Tree Supports</h2><p dir="ltr">Now that we’ve seen the benefits of using tree supports, let’s take a look at the potential downsides.</p><h3 dir="ltr">Longer slicing times</h3><p dir="ltr">The main disadvantage of using tree supports is that the support structures require more processing power than traditional linear supports. Because tree supports have a more complex geometry than linear supports, they take longer to generate in slicing software. This can minimize the benefit of faster support printing times (though rarely negate it).</p><h3 dir="ltr">Less suitable for soluble PVA supports</h3><p dir="ltr">Due to their complexity in shape and geometry, tree supports can also present a challenge if you are using a <a href="https://www.wevolver.com/article/using-soluble-3d-printer-filament-to-build-support-structures" target="_blank">soluble support material such as PVA</a>. PVA is a harder material to print compared to PLA or ABS and some 3D printers can therefore struggle to achieve the finer shapes that characterize the tops of tree supports. Cura therefore recommends using its tree support function primarily for non-soluble support materials.</p><h3 dir="ltr">Cura tree support pros and cons summary:</h3><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>Cura Tree Support Pros</strong></p></td><td><p dir="ltr"><strong>Cura Tree Support Cons</strong></p></td></tr><tr><td><p dir="ltr">Less material waste</p></td><td><p dir="ltr">Longer slicing times</p></td></tr><tr><td><p dir="ltr">Faster printing times</p></td><td><p dir="ltr">Less suitable for soluble supports</p></td></tr><tr><td><p dir="ltr">Smoother surface finish</p></td><td><br></td></tr><tr><td><p dir="ltr">Easier post-processing</p></td><td><br></td></tr></tbody></table></div><h2 dir="ltr">When to use Cura Tree supports?</h2><p dir="ltr">While the disadvantages of Cura tree supports are minimal compared to the advantages, there is still a time and a place to use them. In some cases, standard 3D printing supports may be more beneficial. In others, tree supports are the clear way to go. There are three main scenarios where tree supports make the most sense.</p><h3 dir="ltr">If visual quality is a priority</h3><p dir="ltr">First, if you are printing an object where the visual quality is of the utmost importance, tree supports are highly beneficial. Because tree supports are designed to have fewer connection points to the 3D printed part, removal is easy and results in fewer marks or imperfections on the part’s surface.&nbsp;</p><h3 dir="ltr">If you want to reduce material waste</h3><p dir="ltr">Second, if you are trying to consume less filament, tree supports will generally use less material because they are hollow shells. If you need greater stability, you can also choose to print tree supports with a low infill density. Using less material for supports will help you minimize material waste and cut back on material costs in the long run.</p><h3 dir="ltr">If tight tolerances are needed</h3><p dir="ltr">Third, tree supports are highly beneficial if you are printing a component that requires tight tolerances. Because regular supports sometimes need to be cut off, makers need to sand down the support remnants from the part surface. Sanding and other post-processing steps can influence the part’s dimensional accuracy. Tree supports on the other hand require minimal post-processing (often no post-processing) and can be removed without affecting the part’s tolerances.&nbsp;</p><p dir="ltr"><strong>Recommended reading:&nbsp;<a href="https://www.wevolver.com/article/how-to-remove-supports-from-3d-prints" target="_blank">How to Remove Supports from 3D Prints</a></strong></p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Whether you are a beginner or experienced maker, it is important to know what features are at your disposal when it comes to 3D printing. Still a relatively new option in Cura slicer, tree supports provide many advantages that makers may not yet be familiar with. With the knowledge in this article, however, you should be prepared to make the most out of automated tree supports and their print settings.</p><p dir="ltr">As 3D printing continues to evolve, experimenting with tree supports in your next project can unlock new levels of creativity and efficiency. Whether you're working on intricate prototypes, custom parts, or artistic creations, incorporating tree supports can significantly enhance your 3D printing outcomes.</p><h2 dir="ltr">Frequently Asked Questions (FAQs)</h2><p dir="ltr"><strong>Q: Are Cura tree supports compatible with all 3D printers?&nbsp;</strong></p><p dir="ltr">A: Cura tree supports are compatible with most FDM (Fused Deposition Modeling) printers. However, it's always best to check your printer's specifications and ensure you're using the latest version of Cura for optimal compatibility.</p><p dir="ltr"><strong>Q: Can tree supports be used with all types of filaments?&nbsp;</strong></p><p dir="ltr">A: Tree supports work well with most common filaments like PLA, ABS, and PETG. For less common 3D printing materials, it's recommended to test and adjust settings accordingly. Some flexible filaments may require special considerations and soluble filaments like PVA are generally not recommended for use with tree supports.</p><p dir="ltr"><strong>Q: How do I optimize tree support settings for very small, detailed prints?&nbsp;</strong></p><p dir="ltr">A: For small, detailed prints, consider reducing the branch diameter and increasing the branch density. Adjust the "Support Roof" settings to ensure proper support for fine details. Experiment with different overhang angles to find the optimal balance between support and print quality.</p><p dir="ltr"><strong>Q: Are tree supports suitable for large-scale prints?&nbsp;</strong></p><p dir="ltr">A: Yes, tree supports are excellent for large-scale prints. They can significantly reduce material usage and print time compared to traditional supports. For very large prints, consider increasing the branch diameter and adjusting the branch angle for added stability.</p><p dir="ltr"><strong>Q: How do tree supports compare to traditional supports in terms of print time?&nbsp;</strong></p><p dir="ltr">A: In most cases, tree supports reduce print time compared to traditional supports. The exact time savings depend on the model's complexity. However, the slicer generating time for tree supports is slower than for linear supports.</p><p dir="ltr"><strong>Q: Are there any specific model orientations that work best with tree supports?&nbsp;</strong></p><p dir="ltr">A: While tree supports are versatile, orienting your model to minimize overhangs can optimize their effectiveness. For mechanical parts, consider orientations that align the broadest flat surfaces with the build plate.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Tree supports: What are they and how do they work? [Internet]. Ultimaker, 2024. Available from:&nbsp;<a href="https://ultimaker.com/learn/tree-supports-what-are-they-and-how-do-they-work/" target="_blank">https://ultimaker.com/learn/tree-supports-what-are-they-and-how-do-they-work/</a>&nbsp;</p><p dir="ltr">[2] UltiMaker Cura - Support settings [Internet]. Ultimaker, March 3, 2024. Available from:&nbsp;<a href="https://support.ultimaker.com/s/article/1667417606331" target="_blank">https://support.ultimaker.com/s/article/1667417606331</a>&nbsp;</p>

Cura tree supports are a relatively new feature that offers several benefits, like less material consumption and easier support removal

Everything you need to know about Cura tree supports, including how they work, key slicer settings, their pros and cons, and when to use them.

Your Guide to Cura Tree Supports

Common lines in 3D prints include layer lines

Unwanted lines in 3D prints can show up for many reasons and take different forms. Here we look at the most common types of lines in 3D prints and how to eliminate them.

Lines in 3D Prints: How to Fix Them

<p dir="ltr" id="isPasted">Most newcomers to 3D printing don’t think about retraction settings until they’ve succumbed to stringing. This is a common printing problem during which the nozzle leaks excess filament over the printed part, resulting in a mess of plastic strands that look like cobwebs.</p><p dir="ltr">Stringing can be caused by several factors. Too much heat in the hot end is a common culprit, while some materials — <a href="https://www.wevolver.com/article/petg-print-settings-adjusting-temperature-speed-retraction-to-improve-printing" target="_blank">PETG</a>, for instance — are more prone to stringing than others.[1] When reducing the printing temperature doesn’t fix the problem, a great way to counter stringing is to adjust the retraction settings found in software like Cura, the popular slicer owned by 3D printer company UltiMaker.</p><p dir="ltr">There are several Cura retraction settings to play with, including retraction distance, retraction speed, and minimum travel distance, and knowing how these parameters affect the printing process is a great weapon in the fight against stringing. This article lists all of the Cura retraction settings available to users, explaining what they do and how they can be optimized to suit different prints.</p><h2 dir="ltr">What is Retraction?</h2><p dir="ltr">During FDM/FFF 3D printing, the printer’s extruder uses gears to move plastic filament to the hot end, where the filament is melted and pushed through a nozzle onto the build area below. Meanwhile the print head is constantly moving around in order to deposit the molten material in the right places.</p><p dir="ltr">Every now and again, the print head needs to move from one area to another without depositing any material. In 3D printing terminology, this type of movement is called travel. However, since there is always a bit of melted filament in the printer’s hot end, the plastic can sometimes accidentally ooze out of the nozzle and onto the build during travel. This is a problem for printer users, because that oozed material can cause an ugly, stringy mess over the printed parts.</p><p dir="ltr">One way to counter oozing and stringing is retraction.[2] This is when the extruder stops pushing the filament towards the hot end and pulls it back instead. It can do this by reversing the direction in which the extruder gears move.</p><p dir="ltr">Retraction cannot magically eliminate oozing, because the already-melted section of the filament cannot itself be retracted. However, by retracting the solid section of filament immediately above the melt zone, pressure is relieved on the molten material, making it less likely to ooze out from the nozzle during travel movements.</p><p dir="ltr" id="isPasted"><strong>Recommended reading: <a href="https://www.wevolver.com/article/3d-printer-stringing-how-to-fix-it" target="_blank" rel="noopener noreferrer"><em>3D Printer Stringing: How to Fix It</em></a></strong></p><h2 dir="ltr">Retraction for Different Extruders and Materials</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1725442507473-3d_printer_extruder_closeup.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="bowden"><span class="fr-inner">Bowden extruders require a greater retraction distance than direct drive extruders</span></span></span></p><p>The ideal Cura retraction settings can depend on various factors, including the chosen filament and the type of extruder used on the 3D printer. Some materials require more extensive retraction to prevent issues like oozing and stringing, while the mechanics of the extruder also affect how the process works.</p><h3>Extruder Considerations</h3><p id="isPasted">Retraction settings vary a lot between Bowden and direct drive extruders due to differences in filament path length and control.&nbsp;</p><p>Bowden extruders have a longer filament path, which increases the likelihood of stringing and requires greater retraction distances, typically between 4 to 6 mm. The longer distance helps counteract the elasticity in the Bowden tube, reducing oozing during non-printing moves. Retraction speed also needs to be adjusted; slightly slower speeds around 30 to 45 mm/s are common to prevent filament grinding.</p><p>In contrast, direct drive extruders have a shorter, more direct filament path, allowing for more precise control. Retraction distances for direct drive systems are usually much shorter, around 1 to 2 mm, because the filament is retracted directly from the hotend. Retraction speeds can be faster, often ranging from 35 to 60 mm/s, due to the reduced risk of filament grinding or stringing.</p><p><strong>Recommended reading:&nbsp;</strong><a href="https://www.wevolver.com/article/bowden-extruder" target="_blank" rel="noopener noreferrer"><em><strong>Direct Drive vs Bowden Extruder for 3D Printing</strong></em></a></p><h3>Material Considerations</h3><p id="isPasted">Different filaments require different retraction settings due to variations in material properties like viscosity, elasticity, and temperature sensitivity.&nbsp;</p><p>For example, flexible filaments like TPU may need shorter retraction distances and slower speeds to avoid filament deformation or jams. In contrast, rigid materials like PLA can tolerate longer retraction distances and faster speeds because they are less likely to stretch or compress. PETG is prone to stringing and might require lower retraction speeds.</p><h2 dir="ltr">Cura Retraction Settings</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI1MzgxMTc2NTExLXJ0YUltYWdlLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="cura"><span class="fr-inner">Adjusting retraction settings in Cura can solve oozing and stringing issues (image credit:&nbsp;<a href="https://support.makerbot.com/s/article/1667411336660" target="_blank" rel="noopener noreferrer">UltiMaker</a>)</span></span></span></p><p dir="ltr" id="isPasted">By adjusting Cura retraction settings, the slicer can adjust the <a href="https://www.wevolver.com/article/your-guide-to-3d-printing-g-code" target="_blank" rel="noopener noreferrer">g-code</a> sent to the printer, altering the retraction process in various ways. Users can specify when retraction should happen, how much filament should get retracted, how quickly it should get retracted, and more.</p><p dir="ltr">Cura’s retraction settings can be found in <strong>Print Setup</strong>. Most are grouped under <strong>Material</strong> settings, while some others are grouped under <strong>Travel</strong>. The first two retraction settings, which can be checked or unchecked, are fairly self-explanatory: “Enable retraction” allows users to toggle whether retraction takes place at all, while “Retract at layer change” instructs the printer to perform retraction once a 2D layer is complete.</p><p dir="ltr">The remaining Cura retraction settings, most of which are defined using numerical values, may be less intuitive to beginners. Related settings like print speed and coasting are not discussed here, but may be adjusted in conjunction with retraction settings to deliver the best results.</p><p dir="ltr">Some users find that UltiMaker Cura is better than rival slicers like PrusaSlicer for reducing stringing. This may be down to its more customizable retraction settings and advanced features like "Combing Mode." Combing Mode minimizes the number of non-printing moves that cross open spaces, reducing the chances of stringing. Additionally, Cura's broader range of material profiles and plugins, such as the AutoTowers Generator, can help optimize settings more precisely for different filaments, leading to cleaner prints.</p><h3 dir="ltr">Retraction distance</h3><p dir="ltr">Retraction distance refers to the amount of filament pulled back by the extruder.[3] If the value is greater, then a longer length of filament is retracted.</p><p dir="ltr">The retraction distance is usually set in the range of 0.5–15 mm, depending on the extruder and material type. A greater retraction distance can help to prevent stringing, but this can cause stress on the filament and potentially cause clogs, as well as resulting in longer print times.</p><p dir="ltr">Bowden and direct-drive extruders require different retraction distances. Bowden extruders can require a retraction distance of up to 15 mm, while direct-drive systems generally only need a few millimeters.</p><h3 dir="ltr">Retraction speed</h3><p dir="ltr">Retraction speed is the rate at which the extruder retracts the filament. In Cura, retraction speed settings are divided into two values:</p><ul><li dir="ltr"><p dir="ltr"><strong>Retraction retract speed</strong> is the speed (in mm/s) at which the extruder pulls back the filament</p></li><li dir="ltr"><p dir="ltr"><strong>Retraction prime speed</strong> is the speed (in mms) at which the extruder returns the filament back to its original position at the tip of the nozzle</p></li></ul><p dir="ltr">Faster retractions can help to prevent oozing but run the risk of damaging the section of filament by grinding it. Most users set their retraction speed in the range of 30–80 mm/s.</p><h3 dir="ltr">Retraction extra prime amount</h3><p dir="ltr">During retraction, priming is when the extruder returns the filament to its original position — by pushing it forwards after it has temporarily pulled it backwards. However, since a bit of material may have oozed during the travel movement, it can be helpful to extrude extra material to compensate for this loss.</p><p dir="ltr">The retraction extra prime amount is defined in cubic millimeters. A greater value helps to build pressure in the nozzle, which can prevent issues like under-extrusion. However, the required amount depends on several factors, including nozzle size and travel distance.</p><p dir="ltr">Cura users can download <a href="https://github.com/Pheneeny/CuraPlugin-ScalableExtraPrime#:~:text=ScalableExtraPrime-,A%20Cura%20plugin%20to%20add%20a%20scaling%20amount%20of%20extra,the%20end%20of%20the%20travel." target="_blank">plugins</a> that set the retraction extra prime amount automatically based on travel distance.</p><h3 dir="ltr">Retraction minimum travel</h3><p dir="ltr">During printing, a travel move is when the print head moves from one area of the build to another without depositing material. Sometimes the print head travels just a few millimeters, but sometimes it moves all the way across the build.</p><p dir="ltr">The retraction minimum travel distance setting allows users to define whether the printer should perform retraction even during short travel moves, or just for very large jumps. A small minimum travel distance (in mm) can help to prevent stringing but can cause issues like filament grinding.</p><p dir="ltr">Though not specifically a retraction setting, users can also adjust parameters like travel speed, with faster travel moves potentially reducing oozing and stringing.</p><h3 dir="ltr">Maximum retraction count</h3><p dir="ltr">This print setting lets users set a maximum number of retractions on a given length of material (defined in the “Minimum extrusion distance window” box).</p><p dir="ltr">Setting a maximum retraction count can be useful, because repeatedly retracting the same piece of filament makes it more susceptible to grinding, which can ultimately reduce print quality. However, capping retractions can potentially make the print more vulnerable to oozing and stringing.</p><h3 dir="ltr">Nozzle switch retraction</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjUxNTYwODgwOTA1LTNkX3ByaW50ZWRfc2hvZS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib" alt="Nozzle standby"><span class="fr-inner">Cura can enable retraction when the nozzle goes into standby mode</span></span></span></p><p dir="ltr" id="isPasted">Cura can instruct the 3D printer to carry out a retraction when the nozzle is put in standby mode. It offers two adjustable parameters for this situation:</p><ul><li dir="ltr"><p dir="ltr"><strong>Nozzle switch retraction distance</strong> (mm) works in the same way as general retraction distance, but users can set a higher value as there is less negative impact on overall print times</p></li><li dir="ltr"><p dir="ltr"><strong>Nozzle switch retraction speed</strong> (mm/s) works in the same way as general retraction speed</p></li></ul><h3 dir="ltr">Combing</h3><p dir="ltr">Found under&nbsp;Travel&nbsp;settings, combing is a feature that instructs the printer to avoid any travel moves that stray beyond the perimeter of the build.</p><p dir="ltr">Combing can be useful for several reasons. Although it can result in greater travel distances, it allows for a degree of looseness during printing, since any oozing or stringing can take place inside the part and therefore be invisible. This makes retraction less of a necessity and allows users to print faster, with fewer retractions.</p><p dir="ltr">Users can select from the following combing modes:</p><ul><li dir="ltr"><p dir="ltr">Off</p></li><li dir="ltr"><p dir="ltr">All</p></li><li dir="ltr"><p dir="ltr">Not on outer surface</p></li><li dir="ltr"><p dir="ltr">Not in skin</p></li><li dir="ltr"><p dir="ltr">Within infill</p></li></ul><h3 dir="ltr">Z-Hop</h3><p dir="ltr">Sometimes called vertical travel, Z-Hop is a feature of Cura that instructs the print head to move upwards (or the build platform to move downwards) while retracting and making a travel move. This can prevent the nozzle from dragging along the top of the build and causing scratches or blobs.</p><p dir="ltr">If Z-Hop is enabled, users can adjust the following parameters:</p><ul><li dir="ltr"><p dir="ltr">Z-hop only over printed parts</p></li><li dir="ltr"><p dir="ltr">Z-hop height</p></li><li dir="ltr"><p dir="ltr">Z-hop after extruder switch</p></li></ul><h2 dir="ltr">Testing Retraction Settings</h2><p id="isPasted">Testing out Cura retraction settings can lead to improved results. A practical approach is using retraction towers, which are retraction test models that vary retraction settings along their height. Each segment of the tower tests a different retraction distance or speed, allowing you to visually inspect the results and identify the optimal settings.</p><p>You can <a href="https://www.thingiverse.com/tag:retraction_test" target="_blank" rel="noopener noreferrer">download pre-made</a> retraction tower test prints from platforms like Thingiverse or design your own.&nbsp;</p><p>For a more automated approach, Brad Kartchner's <a href="https://marketplace.ultimaker.com/app/cura/plugins/Kartchnb/AutoTowersGenerator" target="_blank" rel="noopener noreferrer">AutoTowers Generator</a> plugin for Cura simplifies this process. After installing the plugin, you can generate a custom retraction tower directly within Cura. This plugin allows you to specify a range of retraction settings, such as varying the retraction distance from 2 mm to 8 mm in 1 mm increments. It then automatically creates a model with multiple segments, each representing a different retraction setting.</p><p>Once your retraction tower is printed, closely examine each segment for stringing or other surface defects. The goal during this stage of troubleshooting is to find the segment with the least stringing, which indicates the optimal retraction settings for your specific material and printer.</p><p><strong>Recommended reading: <a href="https://www.wevolver.com/article/pla-bed-temperature" target="_blank" rel="noopener noreferrer"><em>PLA Bed Temperature &amp; Print Temperature Settings</em></a></strong></p><h2 dir="ltr">Conclusion</h2><p dir="ltr">Finding the best retraction settings depends on different factors like the type of material, the purpose of the printed part, and the dimensions of the printed part. However, Cura’s range of adjustable parameters gives users a great degree of control over their prints, meaning that there is a suitable set of retraction settings for any project. Furthermore, many users find that Cura outperforms other slicing software in terms of retraction and the prevention of stringing.</p><h2 dir="ltr">Frequently Asked Questions (FAQ)</h2><p id="isPasted"><strong>What is retraction in 3D printing?</strong></p><p>Retraction is a feature in FDM/FFF 3D printing that helps to minimize stringing by pulling the filament back into the extruder during non-printing moves. This reduces the pressure in the hot end, making it less likely that melted filament will ooze out of the nozzle and create unwanted strands of plastic on your print.</p><p><strong>Why is stringing a common issue, and how can retraction help?</strong></p><p>Stringing occurs when excess filament oozes from the nozzle during travel moves, creating fine plastic strands on the print. Factors like high hot-end temperatures and certain materials (e.g., PETG) make stringing more likely. Retraction can help by pulling the filament back, reducing the chance of oozing and thus minimizing stringing.</p><p><strong>How do retraction settings differ between Bowden and direct drive extruders?</strong></p><p>Bowden extruders require longer retraction distances (typically 4-6 mm) because of their longer filament path, which increases the risk of stringing. Direct drive extruders, with their shorter filament path, typically need only 1-2 mm of retraction.</p><p><strong>How does material type influence retraction settings?</strong></p><p>Different materials require different retraction settings due to their unique properties. For instance, flexible filaments like TPU often need shorter retraction distances and slower speeds to avoid deformation, while rigid materials like PLA can handle longer retractions and faster speeds.</p><p><strong>What are some key retraction settings in Cura, and how do they impact printing?</strong></p><p>In Cura, important retraction settings include retraction distance, speed, and minimum travel distance. Adjusting these can significantly reduce stringing.</p><h2 dir="ltr">References</h2><p dir="ltr">[1] Mueller T, Elkaseer A, Charles A, Fauth J, Rabsch D, Scholz A, Marquardt C, Nau K, Scholz SG. <a href="https://publikationen.bibliothek.kit.edu/1000122259" target="_blank" rel="noopener noreferrer">Eight weeks later—the unprecedented rise of 3D printing during the COVID-19 pandemic—a case study, lessons learned, and implications on the future of global decentralized manufacturing</a>. Applied Sciences. 2020 Jan;10(12):4135.</p><p dir="ltr">[2] How to fix stringing [Internet]. Ultimaker Support. [cited 2022 May 2]. Available from: <a href="https://support.ultimaker.com/hc/en-us/articles/360012016280-How-to-fix-stringing" target="_blank" rel="noopener noreferrer">https://support.ultimaker.com/hc/en-us/articles/360012016280-How-to-fix-stringing</a></p><p dir="ltr">[3] Saini P, Garg D, Choudhury T. <a href="https://ieeexplore.ieee.org/document/8769130" target="_blank" rel="noopener noreferrer">3D Printing: Factors Influencing its Quality and Nature</a>. In2018 International Conference on Computational Techniques, Electronics and Mechanical Systems (CTEMS) 2018 Dec 21 (pp. 480-486). IEEE.</p>

Adjusting retraction settings can prevent stringing and other issues

Retraction is a useful feature of FDM 3D printers that helps to prevent common issues like oozing and stringing. Cura retraction settings enable precise control over the retraction process, but the parameters can be confusing to beginners.

Cura Retraction Settings Explained

PLA, ABS, and PETG are three of the most popular filaments for FDM 3D printing.

In this article, we look at how three of the most commonly used filaments—PLA, ABS, and PETG—compare in terms of printability, properties, and availability.

PLA vs ABS vs PETG: A Comparison of 3D Printing Filaments

<p dir="ltr">Acrylonitrile Styrene Acrylate (ASA) filament has emerged as a popular choice in 3D printing, particularly for applications demanding both durability and resilience. As a copolymer, ASA combines the properties of acrylonitrile, styrene, and acrylate, resulting in a material that offers superior performance in challenging environments. One of the critical factors influencing ASA’s usability is its glass transition temperature (Tg), which plays a pivotal role in determining the filament's suitability for various applications.</p><p dir="ltr">The ASA glass transition temperature, typically about 100°C depending on the material and testing process, is a measure of the temperature at which the polymer transitions from a rigid, glassy state to a more flexible, rubbery state.[1] This property is crucial for assessing the material’s thermal stability and its ability to maintain structural integrity under heat. A high Tg indicates that ASA can withstand elevated temperatures without significant deformation, making it an ideal choice for parts exposed to heat or thermal cycles.</p><p dir="ltr">Additionally, the ASA glass transition temperature affects its performance in outdoor and high-stress environments. The ability of ASA to retain its mechanical properties and resist deformation at elevated temperatures contributes to its suitability for a range of applications, from automotive components to outdoor equipment.[2] This article goes over the basics of ASA glass transition temperature and its relevance to 3D printing.</p><h2 dir="ltr">What is ASA 3D Printing Filament?</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1724850853776-3d_printed_gears.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="asa filament"><span class="fr-inner">ASA filament is comparable in performance to ABS</span></span></span></p><p dir="ltr">Acrylonitrile Styrene Acrylate (ASA) is a widely used thermoplastic in FDM/FFF 3D printing, known for its excellent weather resistance, mechanical strength, and UV stability. Often compared to ABS (Acrylonitrile Butadiene Styrene), ASA offers similar strength and durability but with superior resistance to outdoor conditions, making it ideal for applications that require exposure to sunlight or harsh weather.</p><p dir="ltr">ASA’s UV stability prevents yellowing and degradation, ensuring that parts maintain their color and structural integrity over time. This property makes it a popular choice for automotive components, outdoor fixtures, and any application where prolonged exposure to the elements is a concern. Additionally, ASA is resistant to chemicals and has good impact strength, making it suitable for functional prototypes and end-use parts.</p><p dir="ltr">In terms of printability, ASA is less prone to warping compared to ABS, although it still requires a heated bed and an enclosed build chamber for optimal results. Its slightly lower shrinkage reduces the risk of warping, but careful attention to bed adhesion and temperature control is necessary to minimize these issues. ASA typically prints at temperatures between 240°C and 260°C, with a heated bed set around 90°C to 110°C. The use of an enclosure helps maintain consistent temperature, reducing the likelihood of warping and cracking.</p><p dir="ltr">ASA also supports post-processing, such as sanding, painting, and vapor smoothing, allowing for aesthetically pleasing and functional final products. However, one drawback is the emission of fumes during printing, similar to ABS, which requires adequate ventilation.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/asa-vs-abs" target="_blank"><em>ASA vs ABS: Finding the right 3D printing filament</em></a></strong></p><h2 dir="ltr">ASA Glass Transition Temperature</h2><p dir="ltr">The glass transition temperature (Tg) of Acrylonitrile Styrene Acrylate (ASA) is around 100°C, depending on the material and the testing process. This is a fairly high glass transition temperature compared to other low-cost 3D printing thermoplastics (but low compared to engineering plastics), making ASA particularly suitable for prototyping and low-risk applications where heat resistance and structural integrity are important.</p><p dir="ltr">For comparison, ABS, a close relative of ASA, has a Tg of about 105°C, slightly higher than ASA. Both materials behave similarly during printing, requiring heated beds and enclosed chambers to maintain temperatures above their Tg to ensure proper layer adhesion. However, ASA offers better UV and weather resistance, making it the preferred choice for outdoor applications.</p><p dir="ltr">On the other hand, PLA (Polylactic Acid), another widely used 3D printing material, has a much lower Tg of around 60°C. While PLA is easier to print due to its lower temperature requirements and minimal warping, its lower Tg limits its use in environments where higher temperatures are present. PLA parts can deform or soften under moderate heat, making them unsuitable for outdoor or high-heat applications where ASA would excel.</p><p dir="ltr">Comparatively, materials like PETG (Polyethylene Terephthalate Glycol) have a Tg around 80°C. PETG offers a good balance between ease of printing and heat resistance but lacks the UV stability of ASA, making ASA a better choice for outdoor parts that must endure sunlight and heat without degrading.</p><p dir="ltr">ASA’s Tg ensures that printed parts remain structurally stable and retain their mechanical properties in environments that would challenge lower Tg materials. However, designers must still consider ASA's limitations, ensuring that printed parts do not operate in conditions where temperatures exceed 100°C, as this could lead to softening and loss of strength.</p><h2 dir="ltr">Why Does ASA Glass Transition Temperature Vary?</h2><p dir="ltr">The glass transition temperature (Tg) of ASA (Acrylonitrile Styrene Acrylate) can vary due to several factors related to its composition and processing conditions. ASA is a copolymer, meaning it is made from multiple monomers—acrylonitrile, styrene, and acrylate.[3] The ratios of these monomers can affect the Tg. Variations in the proportions can lead to differences in the polymer's rigidity and thermal properties.</p><p dir="ltr">Additionally, the presence of additives or fillers can influence the Tg. These can include impact modifiers, stabilizers, or colorants, each of which can alter the polymer’s thermal behavior. The manufacturing process also plays a crucial role; factors such as polymerization conditions, cooling rates, and thermal history can impact the final Tg. Variability in these conditions can result in slight changes in the Tg from one batch of ASA to another.</p><p dir="ltr">Finally, the Tg can be affected by the molecular weight of the polymer chains. Higher molecular weight ASA may exhibit a different Tg compared to lower molecular weight variants due to differences in chain entanglement and mobility. Thus, the glass transition temperature of ASA is not fixed but rather a range influenced by its specific formulation and processing history.</p><h2 dir="ltr">Thermal Properties of Different ASA Filament Brands</h2><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI0Njk2ODI3Mjk0LVAxNTMzMDk0LTEwMjR4NTc3LmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 100%px;" class="fr-fic fr-dib" alt="prusament"><span class="fr-inner">Part made with Prusament ASA material (image credit:&nbsp;<a href="https://prusament.com/materials/prusament-asa/" target="_blank" rel="noopener noreferrer">Prusament</a>)&nbsp;</span></span></span></p><p dir="ltr">When 3D printing ASA filament, the ASA glass transition temperature is not necessarily the main property to focus on. This is due to a number of factors, but mainly because the extrusion temperature of a material is closer to its melting point than its glass transition temperature.</p><p dir="ltr">All filament manufacturers offer recommended printing temperatures for their ASA filament, as well as recommended bed temperatures. But many do not specify the glass transition temperature of the product, as it is less relevant for its end use. The table below shows the slight variations in ASA print settings between filament brands.</p><div dir="ltr" align="left"><table><tbody><tr><td><p dir="ltr"><strong>Brand</strong></p></td><td><p dir="ltr"><strong>Glass Transition Temperature</strong></p></td><td><p dir="ltr"><strong>Recommended Printing Temperature</strong></p></td><td><p dir="ltr"><strong>Recommended Bed Temperature</strong></p></td></tr><tr><td><p dir="ltr">Prusament ASA</p></td><td><p dir="ltr">Not specified</p></td><td><p dir="ltr">255°C - 265°C</p></td><td><p dir="ltr">105°C - 115°C</p></td></tr><tr><td><p dir="ltr">FormFutura ApolloX</p></td><td><p dir="ltr">98°C</p></td><td><p dir="ltr">235°C - 255°C</p></td><td><p dir="ltr">80°C - 100°C</p></td></tr><tr><td><p dir="ltr">Filamentum ASA extrafill</p></td><td><p dir="ltr">Not specified</p></td><td><p dir="ltr">240°C - 255°C</p></td><td><p dir="ltr">80°C - 105°C</p></td></tr><tr><td><p dir="ltr">Polymaker PolyLite ASA</p></td><td><p dir="ltr">97.8°C</p></td><td><p dir="ltr">240°C - 260°C</p></td><td><p dir="ltr">75°C - 95°C</p></td></tr><tr><td><p dir="ltr">eSun ASA</p></td><td><p dir="ltr">Not specified</p></td><td><p dir="ltr">240°C - 270°C</p></td><td><p dir="ltr">90°C - 110°C</p></td></tr></tbody></table></div><h2 dir="ltr">High-Temperature Performance of 3D Printed ASA</h2><p dir="ltr">3D printed ASA (Acrylonitrile Styrene Acrylate) is known for its good temperature resistance and UV resistance for its price point, making it a preferred material for outdoor and high-temperature applications. This property is also particularly advantageous for parts that undergo thermal cycling.</p><p dir="ltr">In terms of UV resistance, ASA excels compared to other common 3D printing materials like ABS. ASA’s chemical composition includes a high level of acrylate, which provides better protection against UV degradation. This makes ASA highly resistant to yellowing and physical degradation when exposed to sunlight, ensuring that printed parts retain their mechanical properties and aesthetic appearance over time. The inherent UV stability of ASA is beneficial for outdoor applications, such as automotive parts, construction components, and various outdoor equipment.</p><p dir="ltr">To enhance the heat resistance of ASA 3D prints, consider the following strategies:</p><h3 dir="ltr">Optimize Print Settings</h3><p dir="ltr">Increase the extrusion temperature and print bed temperature to ensure better layer adhesion and reduce internal stresses. A higher nozzle temperature (typically between 240°C and 260°C) ensures the material is fully fused, leading to stronger, more heat-resistant prints. Slower print speeds can also improve inter-layer bonding, contributing to overall thermal stability.</p><h3 dir="ltr">Annealing</h3><p dir="ltr">Post-process the ASA print by annealing it in an oven. Heating the print to a temperature just below the glass transition temperature (around 85°C to 95°C) for a few hours can relieve internal stresses and improve the crystallinity of the polymer. This process can enhance the print’s thermal resistance and dimensional stability when exposed to higher temperatures.</p><h3 dir="ltr">Infill and Wall Thickness Adjustment</h3><p dir="ltr">Increase the infill percentage and wall thickness to reinforce the print. A denser infill and thicker walls create a more robust structure that can better resist deformation under heat. Additionally, using a higher number of perimeters can enhance the print’s rigidity, making it less susceptible to warping or softening when exposed to elevated temperatures.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/what-is-pla-filament-composition-advantages-applications" target="_blank"><em>What is PLA Filament? Composition, Advantages, Applications</em></a></strong></p><h1 dir="ltr">Conclusion</h1><p><span class="fr-img-caption fr-fic fr-dib" style="width: 832px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1724850879343-green_car_side_mirror.jpg" style="width: 100%px;" class="fr-fic fr-dib" alt="car"><span class="fr-inner">ASA's UV resistance makes it suitable for external car parts like mirror housings</span></span></span></p><p dir="ltr">ASA's glass transition temperature (Tg) is an important parameter that influences its mechanical, thermal, and chemical properties. Understanding Tg is helpful for optimizing ASA's performance in diverse engineering applications, from automotive exteriors to electronic housings. However, ordinary 3D printer users should focus on a material’s suggested printing temperature rather than its glass transition temperature to achieve a high level of printing performance.</p><h1 dir="ltr">Frequently Asked Questions (FAQ)</h1><p dir="ltr"><strong>What is the ASA glass transition temperature?</strong></p><p dir="ltr">The glass transition temperature of ASA is around 100°C.</p><p dir="ltr"><strong>What is the ideal printing temperature for ASA?</strong></p><p dir="ltr">ASA filament prints best at an extrusion temperature of around 250°C and a bed temperature of around 100°C.</p><p dir="ltr"><strong>How does ASA compare to ABS?</strong></p><p dir="ltr">ASA has a slightly lower glass transition temperature than ABS. It is therefore fractionally less heat resistant but offers superior UV and water resistance.</p><p dir="ltr"><strong>What are some popular ASA filaments?</strong></p><p dir="ltr">Common ASA filament brands include FormFuture ApolloX, Filamentum ASA extrafill, and Polymaker PolyLite ASA.</p><h1 dir="ltr">References</h1><p dir="ltr">[1] Shen MC, Eisenberg A. <a href="https://www.sciencedirect.com/science/article/abs/pii/0079678667900398" target="_blank">Glass transitions in polymers</a>. Rubber Chemistry and Technology. 1970 Jan 1;43(1):95-155.</p><p dir="ltr">[2] Berzinis A, Andriuli M. <a href="https://www.sae.org/publications/technical-papers/content/1999-01-0847/" target="_blank">Weathering performance of black thermoplastic resins for unpainted automotive exterior applications</a>. SAE transactions. 1999 Jan 1:706-15.</p><p dir="ltr">[3] Breulmann M. <a href="https://www.researchgate.net/publication/230137160_Synthesis_Properties_and_Applications_of_Acrylonitrile-Styrene-Acrylate_Polymers" target="_blank">Synthesis, Properties and Applications of Acrylonitrile±Styrene±Acrylate Polymers</a>. Modern Styrenic Polymers: Polystyrenes and Styrenic Copolymers. 2003 Mar 1:341.</p>

The ASA glass transition temperature is around 100°C. This makes it slightly easier to print than ABS, while it is also better for outdoor applications due to its good UV resistance.

3D Printing

What is 3D Printing: A Comprehensive Guide to its Engineering Principles and Applications

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