Application of the Week: Starwheel

Welcome to our application spotlight series, where we showcase real-world 3D-printed solutions that tackle industrial challenges. Each part we highlight demonstrates how 3D printing can reduce costs, improve efficiency, and unlock new possibilities for manufacturers. In this article, we’re focusing on a 3D-printed starwheel – a vital component in automated packaging lines.

Designed by our Senior Applications Engineer Jeremy Evers and inspired by Krones packaging lines, this custom starwheel highlights the power of 3D printing to deliver enhanced functionality, faster production, and lower costs.

Reinventing the starwheel

In high-speed packaging environments, starwheels play a critical role in maintaining product flow. Traditionally, these parts are expensive and time-consuming to produce, especially when customization is required to handle different bottle shapes or sizes.

Using an UltiMaker 3D printer and PET CF material, our engineer developed a custom starwheel that not only improves bottle handling but also adds valuable monitoring functionality. This innovative part is designed to withstand harsh production environments while enhancing efficiency through real-time line monitoring.

Key features and benefits

Here’s what makes this 3D-printed starwheel stand out:

Customizable design for maximum flexibility

One of the biggest advantages of 3D printing is design adaptability. The starwheel can be easily customized to accommodate different bottle shapes, sizes, and production speeds, making it a versatile solution for diverse industries like food and beverage or pharmaceutical manufacturing.

Durable, high-performance materials

Printed with UltiMaker PET CF (carbon-fiber-reinforced polymer), the starwheel offers excellent abrasion resistance, dimensional stability, and durability. This ensures it can withstand continuous use and maintain peak performance in demanding production environments.

Unlock dual extrusion possibilities

With dual extrusion, even more advanced applications become possible. The starwheel below, was created using Nylon CF Slide for the outer layer and PET CF for the inner core, enabling built-in wear indication. Printed with the new UltiMaker S8 this approach expands design possibilities for high-performance, multi-material parts.

Innovate with UltiMaker

Whether you need to streamline your packaging line, reduce downtime, or explore customized components, 3D printing offers endless opportunities to enhance your operations. Get in touch to discover how UltiMaker's industrial grade solutions can help push your business forward.