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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.The Challenge: Poor Chip Removal and Inconsistent Coolant CoverageThe 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.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. The Solution: A Custom Metal 3D-Printed Coolant RingTo 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.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.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.<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">The Benefits: Enhanced Efficiency, Safety, and Tool LifeThe introduction of the custom 3D-printed coolant ring brought numerous benefits to the machining process:<ol><li data-list-indent="1" data-list-type="bulleted">Better Chip Removal: The optimized design of the coolant ring ensured consistent and effective coolant flow, greatly improving chip removal and reducing the risk of tool damage.</li><li data-list-indent="1" data-list-type="bulleted">Increased Tool Life by a Factor of 20: With improved coolant coverage and chip removal, the tool life was extended dramatically, reducing the frequency of tool changes and lowering operating costs.</li><li data-list-indent="1" data-list-type="bulleted">Improved Process Stability: The ability to remove and reattach the coolant ring without relying on the operator reduced variability and enhanced overall process stability.</li><li data-list-indent="1" data-list-type="bulleted">Three Times Faster Tool Change Time: The streamlined design and ease of reattachment allowed for much quicker tool changes, tripling the speed of this critical process and further enhancing productivity.</li><li data-list-indent="1" data-list-type="bulleted">Safer Manufacturing Environment: The consistent coolant coverage and improved chip removal minimized the risk of fire, contributing to a safer working environment.</li></ol>Conclusion: A Custom Solution for Optimized PerformanceThe 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.

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

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.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.So let’s dive into it!<h3>Automated Packaging Systems</h3>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.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.Starwheel, infeed starwheel and sprockets:<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">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.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.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.<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">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.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.<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"><h3 id="isPasted">Inverter tunnels</h3>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).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).<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">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.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.<h3>Guide Rails</h3>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.<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">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).<h3>Infeed scroll/timing screws</h3>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.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>.<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">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.<h3>LOTO safety tool</h3>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.<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">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.<h3>Wear parts</h3>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.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.<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"><h3 id="isPasted">Materials</h3>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.That being said, when thinking about what material to use, you have to know the requirements:<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>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:<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>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.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.

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

<section id="isPasted">When it comes to inspections in the maritime environment, the status quo has long been marked by challenges that impede efficiency and incur significant costs. Routine vessel inspections, vital for maintaining operational integrity, optimizing fuel efficiency, and ensuring safety underwater, have traditionally relied on divers or drydocking methods, both of which are inherently costly and time-consuming.The emergence of remotely operated vehicles (ROVs) promises a more accessible and cost-effective alternative, yet their usability has been hindered by the perennial problem of navigation beneath vessels' hulls.This article provides a comprehensive exploration of Dead Reckoning and the seminal work undertaken by Deep Trekker in mini ROV technology, with a particular emphasis on its potential to transform routine vessel inspections. The focus is on highlighting the implications for fuel efficiency, defect detection, and the cost-effective optimization of vessel maintenance.This innovative breakthrough was achieved by Deep Trekker’s pioneering work on Dead Reckoning technology. These latest achievements have the potential to advance underwater vessel inspections by providing a practical solution to the long-standing challenge of underwater navigation.<img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/3t6Sd0J8AmQJovMiFiUn2a/a62bd6232bd4c359e78a51496aabe8c7/Group_Glamor_Shot_crop1.jpg" alt="DESCRIPTION HERE" width="800" height="356" class="fr-fic fr-dii"></section><section><h2>Applications of Dead Reckoning with Underwater Robotics</h2>Beyond just hull inspections, Dead Reckoning finds widespread application in the field of underwater robotics, where autonomous vehicles and ROVs navigate complex underwater environments for various tasks, including oceanographic research, underwater surveys, pipeline maintenance, and search and recovery, to name a few.In oceanographic research, ROVs equipped with Dead Reckoning systems can gather data on ocean currents, temperature gradients, water quality, and marine life distribution. By continuously updating their positions through Dead Reckoning calculations, ROVs can execute predefined survey patterns, enabling scientists to study ocean dynamics and ecosystem health.Similarly, in underwater inspections and maintenance operations, ROVs rely on Dead Reckoning to navigate complex underwater structures, such as offshore oil rigs and submerged pipelines. By accurately estimating their positions relative to target objects, ROVs can perform tasks such as visual inspections, structural repairs, and equipment installations with minimal human intervention.Dead Reckoning also plays a vital role in search and recovery (SAR) missions, where time-critical decisions depend on accurate positional information. Deep Trekker ROVs equipped with Dead Reckoning systems can systematically cover large search areas, narrowing down the search radius based on calculated positions and sensor feedback.Overall, the integration of Dead Reckoning with underwater robotics facilitates more effective navigation in challenging underwater environments, enabling a wide range of scientific, commercial, industrial, and humanitarian applications.</section><section><h2>The Significance of Dead Reckoning in Maritime Inspections</h2>Dead Reckoning is a key component in maritime operations, especially in underwater inspections, as it provides a fundamental means of tracking the position and movement of inspection equipment in underwater environments, such as ROVs. This enables inspectors to navigate, track, and collect data accurately in challenging subaquatic settings.When combined with other navigation aids and sensors, Dead Reckoning contributes to the safety, efficiency, and effectiveness of maritime inspections, ensuring that they meet their intended objectives.Here are some key points highlighting the significance of Dead Reckoning in maritime operations:<h3>Navigating Underwater Without GPS or Electronic Aids</h3>Dead Reckoning serves as a valuable alternative for navigation in GPS-denied environments like underwater regions where GPS signals may be obstructed or jammed. In underwater inspection scenarios, GPS signals are unavailable or unreliable due to the water's attenuation of satellite signals. Dead Reckoning can provide positional data when these systems are unavailable, allowing for underwater navigation without the assistance of GPS or optics in underwater environments.By harnessing a combination of inertial sensors, gyroscopes, accelerometers, and sophisticated algorithms, Dead Reckoning enables ROV operators to maintain accurate spatial awareness and navigate with confidence, irrespective of GPS availability.Operators can rely on Dead Reckoning’s positional data to guide the ROV along predetermined routes and conduct thorough inspections, all without the need for GPS or optics assistance.<h3>Maximizing Inspection Efficiency with Position Tracking</h3>Dead Reckoning enables inspectors to continuously estimate the position of Deep Trekker ROVs as they move underwater during inspections. This information is critical for ensuring that the inspection covers the intended area. When you know where you are, you know where you have already inspected, and you know where you need to go next. Up until now, there has not been an effective method for position tracking for underwater ROVs near ships.By integrating various sensors and algorithms, Dead Reckoning provides real-time feedback on the ROV's location, allowing inspectors to maintain control. By employing Dead Reckoning technology, inspectors can monitor the ROV's position relative to predefined waypoints or planned trajectories, ensuring that the inspection remains on course and covers all targeted areas effectively.<img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/76y0rV73H4Knpiq1h0jdGP/654a1b0426b093d3ada261e9c8bb45d7/gif-__ROV_MOVING_ALONG_HULL_OF_SHIP_WITH_TRACK_LINE_FOLLOWING.gif" alt="DESCRIPTION HERE" width="800" height="356" class="fr-fic fr-dii"></section><section><blockquote>"Real-time position tracking enables inspectors to adapt to changing underwater conditions or unexpected obstacles, allowing for dynamic adjustments to the inspection strategy as needed."</blockquote>By maintaining accurate spatial awareness throughout the inspection process, inspectors can assess underwater assets, identify potential issues, and make informed decisions to optimize maintenance and repair activities.<h3>Enhancing Underwater Safety</h3>When working underwater, safety is a primary concern, both for the ROV operators and any accompanying divers - and knowing the location of the ROV and divers is essential for safety.Dead Reckoning helps inspectors ensure that ROVs or divers do not stray into hazardous areas, such as underwater structures, shipwrecks, or areas with strong currents. By utilizing Dead Reckoning for tracking the precise location of ROVs relative to underwater structures and currents, potential risks can be identified and avoided, minimizing the likelihood of accidents or damage to equipment.<h3>Optimizing Maintenance Strategies through Data Driven Insights</h3>Positional data obtained through Dead Reckoning improves the quality of inspection data, enabling inspectors to navigate ROVs to specific areas of interest. This targeted approach ensures that inspections focus on the most important areas, reducing the chance of missing essential details and improving data accuracy.<img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/5sM6RDNMt3mhw0FFcZ4pfK/55f0e7b543ed7c1e8d6b733f221c3aa0/gif-__LOOKING_UP_CLOSE_AT_SHIP_WITH_DEAD_RECKONING_TRACK_LINE_ON_SCREEN.gif" alt="DESCRIPTION HERE" width="800" height="356" class="fr-fic fr-dii">This includes data such as the location of underwater structures, defects, or anomalies, which must be precisely recorded for effective analysis. Higher quality data can lead to more informed decision-making, potentially reducing the need for follow-up inspections that consume additional fuel and resources.The data collected by ROVs utilizing Dead Reckoning technology provides valuable insights that can optimize vessel maintenance strategies. By accurately documenting hull conditions and identifying areas requiring attention, ROVs allow maintenance teams to prioritize repairs, schedule cleaning operations, and implement proactive maintenance measures.This data driven approach minimizes downtime, reduces operational costs, and extends the lifespan of vessels, ultimately raising the bar for operational efficiency and profitability.</section><section><h3>Fuel Efficiency and Resource Management</h3>Dead Reckoning assists in efficient resource management by helping inspectors monitor the progress of inspections. It helps ROVs identify the optimal times to clean the ship, to ensure that the hull remains clear of biofouling. Fuel efficiency in maritime operations can be dramatically improved by regular inspections and keeping the hull clear of marine growth - which can potentially reduce fuel efficiency by up to 40% by creating drag from the rough surface.Minimizing fuel consumption not only saves money but also reduces the environmental impact of maritime operations. Dead Reckoning, by ensuring efficient maintenance schedules, contributes to sustainability efforts by reducing emissions associated with fuel burning.<img data-fr-image-pasted="true" src="https://images.ctfassets.net/kzewhs8e6cvu/5wlYcwl6ZPnGvJmvXR1PbL/23d532b66f95008b4391b9f560b8b9d5/Wed-Aug-7-12-56-13-2019-hi-res-date-removed.jpg" alt="Hull inspection biofouling" class="fr-fic fr-dii"></section><section><h2>Integration of Dead Reckoning with Advanced Sensor Technologies</h2>Dead Reckoning technology is often integrated with advanced sensor technologies to further enhance the capabilities of ROVs during vessel inspections. Deep Trekker’s innovative Sensor Fusion algorithms is a great example of this.Sensors such as acoustic positioning systems, imaging sonars, and 3D mapping cameras complement Dead Reckoning by providing additional spatial awareness and environmental data.This integration enables ROVs to navigate complex underwater environments more effectively and capture comprehensive inspection data for thorough analysis and decision-making.</section><section><h2>Future Prospects and Innovations in ROV-based Vessel Inspections</h2>Dead Reckoning is a fundamental navigation technique that ROVs and underwater vehicles use to estimate their position and navigate in GPS-denied or challenging environments. While it provides continuous position estimates, it's important to combine with other sensor data and correction methods to maintain accuracy, especially in dynamic underwater conditions.In the maritime industry where efficiency, accuracy, and cost-effectiveness are critical to operations, Deep Trekker's Dead Reckoning technology stands as an example of this innovation's potential to reshape long standing industry practices and overcome the historical challenges of underwater navigation.<blockquote>"The ongoing advancements in ROV technology, coupled with the continued refinement of Dead Reckoning algorithms, point to an exciting future for vessel inspections."</blockquote>Innovations such as autonomous navigation, machine learning algorithms, and advanced sensor fusion techniques promise to further enhance the capabilities of ROVs for conducting comprehensive and efficient inspections.As these technologies continue to evolve, ROVs equipped with Dead Reckoning will play an increasingly prominent role in maintaining vessel integrity and ensuring maritime safety in the years to come.</section><section><h2>The Deep Trekker Advantage</h2>Deep Trekker ROVs, engineered with rugged industrial-grade materials, are designed for versatility and durability. They offer immediate deployment and a comprehensive variety of advanced features. These ROVs are highly portable and quick to set up, featuring powerful LED lighting, a live 4K video feed, and up to 360-degree field of view, imaging sonar, and flexible sampling tools.Our experienced team is at your service to offer expert guidance for a wide spectrum of applications, ranging from inspecting hull vessels to water tanks to conducting underwater assessments across various industries. We ensure tailor-made solutions that precisely match your specific requirements. When you're prepared to acquire your Deep Trekker ROV, don't hesitate to <a href="https://www.deeptrekker.com/contact-us" target="_blank">get in touch</a> with us for a <a href="https://www.deeptrekker.com/request-quote" target="_blank">personalized quote.</a></section>

Operator piloting ROV with Dead Reckoning tracking

Discover how Deep Trekker's ROV technology transforms underwater navigation, overcoming traditional challenges in underwater positioning. 

Modernizing Vessel Inspections: Dead Reckoning for Mini ROVs

Explore Voltera's innovative project to create a seven-layer magnesium-zinc battery using printable technology. Developed with Saral Designs and employing the NOVA system, the project focuses on building lightweight, flexible, and environmentally friendly batteries on PET substrates.

The Future of Batteries is Flexible: Printing a Magnesium Zinc Battery with Saral Inks on PET

While the 3D printer itself plays a significant role, the parameters used during the printing process are equally important. This article dives into four critical factors:&nbsp;layer thickness,&nbsp;laser power,&nbsp;scan speed, and&nbsp;hatch distance. Let’s break them down, how they work, and why they matter. 1. Layer Thickness: The Foundation of Detail and StrengthLayer thickness refers to the height of each individual layer of material that is deposited during the printing process. In metal 3D printing, this is typically measured in microns (µm). A smaller layer thickness results in finer detail and smoother surfaces but increases the printing time. Conversely, a larger layer thickness speeds up the process but may result in reduced resolution and potentially weaker bonding between layers.Imagine you are printing a small, intricate part, like a turbine blade. In this case, precision and surface quality are key, so you would use a smaller layer thickness, maybe around 20µm. This ensures that the part’s fine edges and smooth surfaces are accurately captured. However, if you're printing a larger, less detailed object like a simple block for structural support, you might choose a larger layer thickness, such as 50µm, to speed up the process without sacrificing too much in terms of quality. 2. Laser Power: The Fuel Behind the ProcessLaser power determines how much energy is used to melt and fuse the metal powder in each layer. The laser essentially traces the shape of the part, melting the powder in specific areas. The higher the laser power, the more energy is applied to the material.However, laser power must be carefully balanced. Too much power can cause problems, such as excessive heat, which can lead to defects like warping or "mold formation" (unwanted structures due to overheating). On the other hand, too little power may result in incomplete melting, which creates weak or porous parts that can easily break under stress.Consider printing a dense, durable part, like a component that will be used in an engine. You’d want to use enough laser power to ensure the metal fuses solidly. But for lightweight parts, where speed is prioritized, you might opt for a lower power setting, ensuring sufficient bonding while avoiding unnecessary energy use and minimizing defects. 3. Scan Speed: The Dance of Precision and EfficiencyScan speed refers to how quickly the laser moves across the powder bed during printing. Like the other parameters, scan speed must be finely tuned for different materials and designs. Faster scan speeds lead to quicker production, but if the laser moves too fast, it might not deposit enough energy into the material, resulting in poor bonding. If the scan speed is too slow, it can lead to excessive energy deposition, which can cause defects similar to those from high laser power, such as warping.For example, if you are working with a highly conductive material like aluminum, which requires more energy to fuse properly, a slower scan speed may be beneficial. This allows the laser to apply enough energy to melt the material fully. In contrast, for materials that require less energy, like titanium, you can afford to increase the scan speed, reducing production time without compromising quality. 4. Hatch Distance: Bridging the GapsHatch distance is the distance between adjacent scan lines as the laser moves across the powder bed. Picture the process like mowing a lawn. The laser creates paths or "lanes" as it melts the powder, and the hatch distance controls how much overlap there is between these lanes. Too large a hatch distance can leave un-melted gaps, reducing the density and strength of the part. Too small a hatch distance leads to excessive overlap, which can cause excessive heat buildup, resulting in defects similar to those caused by too much laser power or slow scan speed.Finding the right hatch distance is a balancing act. For parts requiring high density and mechanical strength, like those used in critical aerospace applications, reducing the hatch distance ensures consistent layer bonding and part integrity. But for less critical parts where speed and cost-efficiency are more important, increasing the hatch distance can significantly cut down on build time and material consumption. The Art of Balancing ParametersThese four parameters—layer thickness, laser power, scan speed, and hatch distance—don’t exist in isolation. They interact with each other, meaning that changes to one parameter can affect the others. For example, increasing the laser power might allow for a faster scan speed or a larger hatch distance, but it could also increase the risk of defects if not balanced properly.Achieving the right combination of settings depends heavily on the material being used and the specific goals of the project. For example, a manufacturer aiming for high-density parts may focus on optimizing hatch distance and layer thickness to reduce voids. Conversely, someone seeking faster production times might prioritize scan speed and layer thickness, adjusting laser power and hatch distance accordingly. <iframe width="640" height="360" src="https://www.youtube.com/embed/4uoPwWQviqc??si=PP0ym8aTxoXmADWw&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"></iframe>

Metal 3D printing requires precise control over a variety of parameters to achieve high-quality parts. Whether you're printing aerospace components, medical devices, or complex machinery, understanding the core settings that influence the outcome is crucial. Lets talk about the most important ones.

Importance of Parameters for Metal 3D printing

The road&nbsp;is a&nbsp;dangerous place for everyone, but for motorcycle riders the inherent risks loom particularly large. When a collision occurs, these road users are highly vulnerable with little to no protection compared to drivers and passengers in enclosed vehicles.The main contributors to accidents involving motorcycles include speed, compromised visibility, and a lack of alertness. Some incidents are perhaps unavoidable. Others might be prevented by mitigating the chance of human error, when the consequences of mistakes are potentially devastating.&nbsp;Fortunately, wireless tech-based solutions are emerging as a driving force behind much needed motorcycle safety improvements.&nbsp;<h2>Facing&nbsp;serious&nbsp;facts&nbsp;</h2>The grim reality is that, proportionate to the number of registered vehicles, motorcycle riders tend to be over-represented in fatal and serious injury figures. According to Bus.com motorcycles are the most dangerous form of transport with around 213 deaths for every 1.6 million kilometers traveled by motorcycle. This compares to just 0.11 deaths for every 1.6 million kilometers traveled by bus[1].&nbsp;And in Australia, for example, annual fatality rates per billion vehicle kilometers travelled are, on average, nearly 30 times higher for motorcycle riders than for vehicle occupants. When it comes to serious injuries, motorcycle riders in the country account for 21.8 percent of all incidents, despite making up only 5.7 percent of registered passenger vehicles[2].&nbsp;Globally, motorcyclists and other powered two-and three-wheeled vehicle riders make up nearly a quarter of the 1.19 million annual road traffic deaths, while 28 percent of deaths due to road accidents are caused by motorcycles, according to the World Health Organization (WHO)[3].<h2>Wireless tech holds the key&nbsp;</h2>To address this enormous challenge and reduce the alarming statistics, innovative developers in the motorcycle equipment sector are turning to advanced technologies. By integrating powerful sensors, location services, and wireless connectivity, smart motorcycle safety gear gives riders a decision-making advantage.&nbsp;&nbsp;Access to live traffic updates, hazard warnings, and optimized routes, among other features, can create a clearer picture of what’s around the corner, and when and how to react.&nbsp;&nbsp;<h2>Heads-up display&nbsp;for helmets&nbsp;</h2>German motorcycle accessories company TILSBERK, for example, has developed a wireless display designed to attach to the user’s motorcycle or scooter helmet to provide important information for riders without taking their eyes off the road.&nbsp;&nbsp;Once connected to the user’s smartphone via Nordic&nbsp;<a href="https://www.nordicsemi.com/Products/nRF52840">nRF52840</a>&nbsp;SoC-enabled&nbsp;<a href="https://www.nordicsemi.com/Products/Wireless/Bluetooth-Low-Energy">Bluetooth LE</a>, the&nbsp;<a href="https://www.nordicsemi.com/Nordic-news/2024/06/TILSBERK-Head-Up-Display-employs-the-Bluetooth-LE-connectivity-of-the-Nordic-nRF52840-SoC">TILSBERK Head-Up Display</a>&nbsp;(HUD) virtual display includes key riding metrics, including navigation prompts, lane indicators, speed limits, speed warnings, incoming calls, compass readings, smartphone charging status, and time. It also offers both a satellite navigation system and a comprehensive tour planning tool.&nbsp;&nbsp;As Mirko Zabel, Team Leader Marketing at TILSBERK explains, eliminating the need to glance down at traditional displays or navigation devices helps to significantly enhance concentration levels and safety while riding.&nbsp;<h2>Motorcycle navigation via sunglasses&nbsp;</h2>Elsewhere, a pair of sunglasses also double as a motorcycle navigation HUD. The lightweight Blucap Moto sunglasses integrate Nordic’s nRF52840 SoC to provide Bluetooth LE wireless connectivity between the sunglasses and the rider’s smartphone, as well as the handlebar-mounted remote control. The remote control employs Nordic’s nRF52810 SoC to enable wireless connectivity.&nbsp;&nbsp;Once the sunglasses are paired to the user’s smartphone, riders can use the fully featured Blucap Go navigation app to relay in-ride directions and other important information from the smartphone to the sunglasses’ high brightness MicroLED-powered HUD. Directions and other important information are displayed in the rider’s peripheral vision ensuring they receive timely navigation assistance, again without taking their eyes off the road, or being distracted by a handlebar-mounted smartphone.&nbsp;Zhu Ning, Founder and CEO of Blucap, claims eliminating the need to mount a phone on the handlebar for navigation allows the Blucap Moto sunglasses to eliminate distractions and safety risks. The solution wouldn’t be viable without wireless technology; the Bluetooth LE wireless connectivity has enabled Blucap to design a minimalist HUD system that functions like ordinary sunglasses with no distractions to the rider at all, says Ning.<h2>A safer&nbsp;road ahead&nbsp;</h2>More and more connected motorcycle safety solutions are hitting the market to help prevent riders from hitting other vehicles, pedestrians, the surface of the road, or infrastructure and environmental hazards like signposts and trees.&nbsp;One forecast by MarketsandMarkets projects the global connected motorcycle market will reach $757 million by 2027, up from $55 million in 2021, representing a CAGR of 54.7 percent during the forecast period[4]. This strong growth forecast is being driven in large part by the rising demand for better motorcycle safety and security, along with the prevalence of powerful edge computing and Cloud services, according to the analyst.&nbsp;It appears the road to greater motorcycle safety—and consequently fewer accidents causing fatal and serious injury—will be paved by the IoT and advanced wireless tech.&nbsp;<hr>References&nbsp;1.&nbsp;<a href="https://www.bus.com/blog/safest-mode-of-transportation/" rel="noopener">Which Mode of Transportation is the Safest?</a> Bus.com, July 2020 &nbsp; 2.&nbsp;<a href="https://www.bitre.gov.au/sites/default/files/documents/road_trauma_australia_2020_statistical_summary.pdf" rel="noopener" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Road trauma Australia 2020 statistical summary.</a> Australian Department of Infrastructure, Transport, Regional Development and Local Government, 2020&nbsp; 3.&nbsp;<a href="https://www.who.int/publications/i/item/9789240086517" rel="noopener">Global Status Report on Road Safety 2023.</a> WHO, December 2023&nbsp; 4.&nbsp;<a href="https://www.marketsandmarkets.com/PressReleases/connected-motorcycle.asp" rel="noopener">Connected Motorcycle Market – Global Forecast to 2027.</a> MarketsandMarkets, 2021&nbsp;

Wireless tech-based solutions are emerging as a driving force behind much needed motorcycle safety improvements. 

Wireless motorcycle safety solutions protect riders on the road

As manufacturers face increasing operational costs, labor shortages, and the need for greater efficiency, AI and Machine Learning (ML) have become critical technologies for driving innovation. The recently released Edge Impulse Manufacturing Dive Survey Report highlights key trends and insights about AI adoption in the manufacturing sector. This article will delve into these findings, exploring how AI is reshaping the industry and why manufacturers should embrace this shift.Download your free copy:<table id="isPasted"><tbody><tr><td><h3>Discover the 5 AI Trends Transforming Manufacturing</h3><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzI4NTU5OTYwNTIyLUVkZ2UgSW1wdWxzZS5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" class="fr-fic fr-dii">The whitepaper, "5 Rising Trends for AI Adoption in Manufacturing," offers key insights into how artificial intelligence is transforming manufacturing processes. It explores survey data from over 150 industry leaders, revealing that optimizing production and improving product quality are top goals driving AI adoption. The report also discusses the rise of AI solutions for worker safety, real-time insights to boost profitability, and the growing importance of internal expertise in implementing AI. Download the full whitepaper to gain a deeper understanding of these trends and how AI/ML is shaping the future of manufacturing.<a href="https://form.jotform.com/242533284499365" target="_blank" rel="noopener noreferrer" class="button-main-action">DOWNLOAD YOUR FREE COPY</a></td></tr></tbody></table><h3>The Primary Goal: Optimizing Production with AI</h3>The report's first major finding is that optimizing production stands as the top priority for manufacturers adopting AI. In today's fast-paced market, efficiency is key. AI allows manufacturers to streamline their processes, reduce downtime, and maintain consistent output quality. Through real-time monitoring of production lines, AI algorithms can detect inefficiencies or anomalies long before they affect productivity.With the advent of edge AI, processing power has moved closer to the source of data, enabling manufacturers to make real-time decisions without relying on cloud connectivity. This not only minimizes latency but also ensures higher privacy and data security, making it an ideal solution for industries requiring rapid, on-site responses.<h3 id="isPasted">Quality Assurance: The Dominant Business Driver for AI</h3>Beyond production efficiency, quality control is another driving force for AI adoption. According to the report, 67% of respondents cited product quality as their primary business driver for leveraging AI. Consistent product quality is essential in maintaining a competitive edge and preserving brand reputation. AI and ML models can help manufacturers ensure that products meet high standards by automating inspection processes and identifying potential defects at earlier stages of production.For example, computer vision integrated with AI can monitor visual anomalies in products, flagging defects with unparalleled speed and accuracy. This technology enables manufacturers to catch and address quality issues in real-time, preventing costly recalls or waste.<h3 id="isPasted">Real-Time Insights: Enhancing Safety and Profitability</h3>Another significant takeaway from the report is that manufacturers are increasingly using real-time insights from AI to improve not only profitability but also worker safety. By deploying AI-driven monitoring systems, manufacturers can gather data on equipment health, environmental conditions, and worker behavior to prevent accidents before they happen. In the general market sample surveyed, 62% of respondents indicated that they are likely to implement AI for worker safety.AI-based predictive maintenance, for example, can predict equipment failures, reducing downtime and maintenance costs while keeping workers safe. This combination of profitability and safety makes AI an indispensable tool in modern manufacturing environments.<h3>The Rise of Edge AI in Manufacturing</h3>Edge AI is a central theme in the report, particularly because of its ability to bring ML models directly to the manufacturing floor. Unlike traditional AI approaches that rely on cloud-based servers, edge AI enables devices at the "edge"—such as machinery and sensors—to process data locally. This shift offers numerous benefits: lower latency, reduced bandwidth requirements, enhanced privacy, and improved data security.Edge AI is especially valuable in applications requiring immediate action, such as equipment monitoring, process optimization, and environmental tracking. For manufacturers, the ability to act on data as soon as it is generated is critical for maintaining seamless operations and avoiding costly interruptions.<h3>Internal Expertise: The Key to Successful AI Implementation</h3>One of the most notable challenges highlighted in the report is the lack of internal expertise. While AI adoption is on the rise, many manufacturers struggle with integrating AI into their existing workflows due to a shortage of skilled personnel. This underscores the importance of developing a well-rounded, knowledgeable workforce or partnering with AI solution providers who understand the nuances of AI and ML deployment in industrial settings.The report stresses that to fully realize the potential of AI, manufacturers need to cultivate internal expertise or collaborate with experienced technology partners. Whether it’s training existing employees in AI technologies or hiring dedicated AI specialists, developing internal capabilities is essential for long-term success.<h3>Seizing the AI Opportunity in Manufacturing</h3>AI and ML are set to transform the manufacturing sector in profound ways, from improving production efficiency and quality control to enhancing worker safety and operational resilience. As the report makes clear, manufacturers who can successfully integrate AI into their processes will be well-positioned to thrive in a rapidly evolving industry.For those looking to stay ahead of the curve, downloading the full Edge Impulse Manufacturing Dive Survey Report is a must. It provides a comprehensive overview of AI’s role in shaping the future of manufacturing and offers actionable insights for those eager to implement AI-driven solutions in their operations.Download the report to explore how AI can drive your manufacturing success in the coming decade:<iframe id="JotFormIFrame-242533284499365" title="Edge Impulse Form" allowtransparency="true" src="https://form.jotform.com/242533284499365" frameborder="0" style="min-width:100%;max-width:100%;height:900px;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">&nbsp;&nbsp; </iframe>

Discover how AI is optimizing manufacturing by increasing quality control, reducing downtime and boosting efficiency.

The Path to Smarter Manufacturing: 5 AI Trends You Need to Know

Continuously promote the implementation of industry applications to the ground Unitree B2 beyond the limit Maximum speed of 6m/s, sustained load of 40kg and sustained walking endurance of 5h. The comprehensive performance is two to three times that of existing quadruped robots worldwide! Adaptable to all terrains, large load, long-lasting endurance, and super athletic performance! Evolve, evolve, and evolve again! More introduction: www.unitree.com/en/b2 <h2> </h2>

Continuously promote the implementation of industry applications to the ground Unitree B2 beyond the limit Maximum speed of 6m/s, sustained load of 40kg and sustained walking endurance of 5h. The comprehensive performance is two to three times that of existing quadruped robots worldwide! 

Unitree releases B2, beyond the limits of hyper-evolution

Manufacturing

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

Investigating the basics of six-axis robots, how they are structured, the key components, advantages and applications in the industrial sector


What is a Six Axis Robot: Exploring the Versatile Powerhouse of Industrial Automation

Industrial process automation is changing manufacturing by using technology to reduce the need for human involvement. From robots assembling products to smart systems managing inventory, factories are being transformed. This article will explore the successful elements behind industrial automation.

Industrial Process Automation: The Future of Manufacturing

Delve into the basics of absolute encoders, its applications, advancements in technologies, calibration techniques, and the advantages over encoder types.


Absolute Encoder: Precision Positioning in the Digital Age

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.<h2 dir="ltr">Why do you need support structures?</h2>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;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;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.<h2 dir="ltr">Linear supports vs Tree supports</h2>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]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;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><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU0NTg0NDgzMzY4LXRyZWVfc3VwcG9ydC5qcGciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" width="624" height="416" class="fr-fic fr-dii" alt="Ultimaker 3D printer while 3D model">Unlike linear supports, tree supports wrap around the 3D model, providing support directly where needed.<h2 dir="ltr" id="isPasted">How Cura Tree Supports Work</h2>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;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;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).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]:<div dir="ltr" align="left"><table><tbody><tr><td>Support Placement</td><td>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.</td></tr><tr><td>Support overhang angle</td><td>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°.</td></tr><tr><td>Support branch angle</td><td>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.</td></tr><tr><td>Support branch distance</td><td>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.</td></tr><tr><td>Support branch diameter</td><td>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.</td></tr><tr><td>Collision resolution</td><td>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.</td></tr></tbody></table></div><h2 dir="ltr">The Pros of Cura Tree Supports</h2>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.<h3 dir="ltr">Less material waste</h3>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;<h3 dir="ltr">Faster printing time</h3>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.<h3 dir="ltr">Smoother surface finish</h3>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.<h3 dir="ltr">Easy support removal</h3>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.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><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjU0NTg0NDM0ODI5LXRyZWUtc3VwcG9ydC1leGFtcGxlLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="Cura 3D model with tree supports">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><h2 dir="ltr" id="isPasted">The Cons of Cura Tree Supports</h2>Now that we’ve seen the benefits of using tree supports, let’s take a look at the potential downsides.<h3 dir="ltr">Longer slicing times</h3>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).<h3 dir="ltr">Less suitable for soluble PVA supports</h3>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.<h3 dir="ltr">Cura tree support pros and cons summary:</h3><div dir="ltr" align="left"><table><tbody><tr><td>Cura Tree Support Pros</td><td>Cura Tree Support Cons</td></tr><tr><td>Less material waste</td><td>Longer slicing times</td></tr><tr><td>Faster printing times</td><td>Less suitable for soluble supports</td></tr><tr><td>Smoother surface finish</td><td> </td></tr><tr><td>Easier post-processing</td><td> </td></tr></tbody></table></div><h2 dir="ltr">When to use Cura Tree supports?</h2>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.<h3 dir="ltr">If visual quality is a priority</h3>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;<h3 dir="ltr">If you want to reduce material waste</h3>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.<h3 dir="ltr">If tight tolerances are needed</h3>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;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><h2 dir="ltr">Conclusion</h2>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.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.<h2 dir="ltr">Frequently Asked Questions (FAQs)</h2>Q: Are Cura tree supports compatible with all 3D printers?&nbsp;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.Q: Can tree supports be used with all types of filaments?&nbsp;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.Q: How do I optimize tree support settings for very small, detailed prints?&nbsp;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.Q: Are tree supports suitable for large-scale prints?&nbsp;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.Q: How do tree supports compare to traditional supports in terms of print time?&nbsp;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.Q: Are there any specific model orientations that work best with tree supports?&nbsp;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.<h2 dir="ltr">References</h2>[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;[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;

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

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