How to design thin and long parts?

Thin and long parts are more likely to cool unevenly, which can cause the printed part to shrink unevenly, resulting in a distortion in one direction that is different from the nominal shape.

As a general rule, any part with an aspect ratio (length vs. width) greater than 10:1 or any part with a sudden change in its cross-section or a mostly long and thin curved segment is likely to warp, as shown in the picture below:

When designing the part, there are a few things you should keep in mind to lower the chance of this deformation happening:

• Make long walls thicker to make their aspect ratios smaller.

• Don't put ridges and ribs on big, flat areas.

• Change the design of parts that are likely to experience a lot of stress and make the transitions between their cross-sections smoother.

• Make the parts lighter by hollowing them out or adding internal lattices.

Summary:

  • Abrupt cross-section changes
  • Thin, long, curved segments
  • Aspect ratio > 10:1 (length:width)

🛠️ Mitigation: Thicken long walls or hollow the part with lattice fill.

There are four types of parts that can warp when they shrink: (a) thin and long parts, (b) parts with sudden changes in cross-sections, and (c) thin curved surfaces.
Warpage mitigation strategies


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