Application of the Week: Guide Rail

Welcome back to our application spotlight series, where we showcase innovative 3D printing solutions tackling real-world manufacturing challenges. Every week, we dive into how 3D printing helps industries save costs, speed up production, and adapt to changing needs with ease.

This week, we’re keeping production lines running smoothly with a closer look at a 3D printed guide rail system designed for a high-speed bottle packaging line. While conveyor systems and 3D printing might seem like an unusual pair, this application proves just how powerful the combination can be.

Read on to learn more.

Keeping production on track

Guide rail systems are an important feature of conveyor lines, especially in food and beverage production. They ensure bottles, cans, and other containers stay perfectly aligned as they speed through straight sections, curves, and corners. But when products vary in size or shape, traditional guide rails can be costly and slow to adapt. That’s where 3D printing steps up.

The team produced a fully customized guide rail system tailored to their specific packaging line needs. Two materials were used: tough, rigid PET CF Gray for the structural parts, and a low-friction, wear-resistant material for the contact surfaces that guide the bottles safely through the line.

Built for durability, built for change

Worried about wear and tear? No problem. With this clever design, the low-friction wear strips are printed separately and simply slide into the main structure. When the strips show signs of wear, you don’t need to replace the entire rail – just swap in a new strip. It’s fast, cost-effective, and minimizes downtime.

Key features and benefits

Here’s why this 3D printed guide rail system is a game changer for packaging lines:

Fast, affordable replacements

Wear strips alone cost around €7–8 to print, while the full part is about €25. When replacements are this easy and affordable, maintenance becomes a breeze.

Durable, flexible design

By using high-performance PET CF for the structure and a low-friction material for bottle contact, the system delivers both strength and smooth operation.

Minimal downtime

Instead of replacing entire rail sections, operators can quickly slide in new wear strips – no tools, no hassle, and no extended production stops.

Smarter packaging lines with 3D printing

This guide rail application is just one example of how additive manufacturing can drive smarter, more agile production. Whether you need modular replacement parts, custom guides, or on-demand tooling, 3D printing gives you the power to keep production lines moving – quickly, reliably, and affordably. See how UltiMaker could help your businesses innovate.