Solution

Print support-free instead of removing supports

Support structures are not a design feature. They are a consequence of uncontrolled heat — and steering heat flow before the build removes most of the need for them.

14°best demonstrated overhang
−95 %support volume
0.5 hsupport removal, was 8 h
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See it costed

What supports actually cost

Powder, build time, manual removal and damaged surfaces — and on internal geometries, often the decision not to print a part additively at all. Conventionally, an overhang below roughly 45° is considered unprintable without support.

The same part, twice

Drag to remove the supports

Left: prepared conventionally. Right: the same geometry, the same machine and the same material — prepared in GENESIS.

Standard preparation GENESIS Standard preparation GENESIS
−95 %support volume, on this part
8 h → 0.5 hsupport removal per build job
2–3×less post-processing overall

Every support you do not print is powder you do not buy, machine time you do not pay for, and a finishing operation nobody has to do by hand.

How GENESIS solves it

Make the heat visible

Fast Heat Simulation shows where heat accumulates in seconds — intensity and extent, layer by layer.

Adapt the exposure sequence

Smart Hatching changes hatch orientation and sequence locally — for example from the core towards the overhang, and against the shielding-gas flow.

Limit the energy input

Power Control regulates laser power locally, so a thermal peak never forms at the critical spot.

A real serial part, recalculated

One Ti64 aerospace bracket, costed across a full build job — not a projection.

Prepared with standard software

103 €per part
2.472 €per build job
8 hsupport removal per build job

Prepared with GENESIS

73 €per part
1.758 €per build job
0.5 hsupport removal per build job
The bracket, prepared with GENESIS — minimal supports.
The bracket, prepared with GENESIS — minimal supports.
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Read the full case study

Demonstrated overhang angles

20°

Ti64, production machine

0°

on test geometries

−95 %

support volume

Ti64 20° · AlSi10Mg 14° · 316L 20° · IN718 15° · CoCr 20° · M789 25° · AlSi7Mg0.6 25°, from technology evaluations across seven OEM platforms.

The software behind it

GENESIS Print SuiteBuild preparation with physical intelligenceBuild EngineDecisions before the print startsSmart HatchingThe local exposure strategy, derived from physicsPower ControlEnergy input, controlled down to the single hatchGENESIS APISimulation inside your production pipeline

What you are trying to solve

Support-free printingSupport structures are not a design feature. They are a consequence of uncontrolled heat — and steering heat flow before the build removes most of the need for them.Distortion controlDistortion does not happen at random. It follows the heat distribution in the part — and that can be computed and influenced before the build.Process stabilityOn high-power machines, thin walls and sharp corners have forced a compromise: productivity or quality. Locally controlled laser power removes that trade-off.Serial productionSerial production starts where unit costs can be calculated. Deterministic process behaviour is the precondition — and the point at which prototyping becomes production.QualificationBringing a new machine and material combination into service is normally a project. With GENESIS it is a calibration with a clearly defined scope.

Frequently asked questions

How far down does it really go?

On production machines, 20° is demonstrated in Ti64. On test geometries, closed spheres with 0° overhangs were printed entirely without support. The achievable angle depends on material, machine and geometry.

Does it change our process parameters?

No. The approved OEM parameters remain the boundary condition. What changes is how the laser moves, not the parameters it moves with.

What about stem supports?

Self-supporting branches at 25° overhang angles add to this: −52 % support volume, more stiffness against distortion, and room for extra parts underneath.

How quickly do we see a result?

In a pilot on one of your parts. Calibration takes two factors and two build jobs.

Ready to get started?

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