Mechanical parts

Considerations for Mechanical Applications

Strength and Stiffness - Mechanical parts often need to bear loads and maintain their shape under stress. Look for materials with high tensile strength and modulus of elasticity.

Impact Resistance - Parts that experience sudden forces or vibrations need materials that won't crack or shatter on impact.

Fatigue Resistance - Components subject to repeated loading cycles require materials that maintain their properties over time.

Dimensional Stability - Precision mechanical parts need materials that hold tight tolerances and don't warp or creep.

Top Material Recommendations

1. PLA (Polylactic Acid)

An excellent starting point for mechanical parts:

• Easy to print with good dimensional accuracy
• Available from many manufacturers
• Good for prototyping and light-duty applications

2. PETG (Polyethylene Terephthalate Glycol)

Offers a great balance of properties:

• High impact strength
• Good chemical resistance
• Transparent options available
• Easier to print than ABS

3. ABS (Acrylonitrile Butadiene Styrene)

Industry standard for many applications:

• Good impact strength
• High temperature resistance
• Post-processable with acetone
• Wide range of grades available

4. Nylon (PA)

For high-performance applications:

• Excellent strength-to-weight ratio
• Good wear resistance
• Chemical resistance
• Self-lubricating properties

5. Polycarbonate (PC)

Engineering-grade performance:

• Exceptional impact strength
• High temperature resistance
• Excellent dimensional stability
• Optical clarity available

6. TPU (Thermoplastic Polyurethane)

For flexible mechanical parts:

• High elasticity and flexibility
• Excellent abrasion resistance
• Good chemical resistance
• Various shore hardness options

Design Considerations

Print Orientation

• Orient parts to align stress directions with layer lines
• Consider support requirements and surface finish needs
• Plan for anisotropic material properties

Infill Strategy

• Use appropriate infill density (typically 20-40% for mechanical parts)
• Consider infill patterns (gyroid, cubic, or triangular for strength)
• Solid infill for highly stressed areas

Layer Height and Adhesion

• Smaller layer heights for better surface finish and strength
• Ensure good layer adhesion with proper temperatures
• Consider annealing for improved layer bonding

Testing and Validation

Before production use:

1. Stress testing - Verify parts can handle expected loads
2. Fatigue testing - Test cyclic loading scenarios
3. Environmental testing - Confirm performance in operating conditions
4. Dimensional verification - Check critical dimensions and tolerances

Post-Processing Options

• Annealing - Heat treatment to relieve stress and improve properties
• Machining - Secondary operations for critical surfaces
• Vapor smoothing - For ABS parts requiring smooth surfaces
• Threaded inserts - For parts requiring metal threads

Remember that 3D printed parts have different properties than traditionally manufactured ones. Design with the manufacturing process in mind and always test critical applications thoroughly.