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.
