Which Material is Best? Am I Overlooking Something?
Hey everyone, I have been printing clips for hard hats and selling them online for a little over a year now. I'm starting to get feedback that after 2 months or so some clips are breaking. Some of which are breaking in places that I cannot physically break by hand if I try. I currently print everything in Polymaker PETG on a Prusa MK4 without an enclosure. 100% infill, the Prusaslicer stock .20 STRUCTURAL print settings with the fan off.
Does anyone have any thoughts on what might be the culprit? I know that there are some design changes that I can make to support the clips.
I've done some reading about ASA and am wondering if that might be where I should move to, I'm hesitant to do so though since Prusa offer a, non $10k, active heated chamber as far as I know.
Thanks!
RE: Which Material is Best? Am I Overlooking Something?
Have you tried LOTS of top and bottom layers, in preference to 100% infill.
enough top and bottom layers to give no space for infill, tend to be better than 100% infill.
If the green part is one that breaks easily, it may be because all of the right hand side looks to be the same width, which will concentrate leverage (and flexing) on the U Bend at the Bottom, I would suggest making the u bend section thicker, or making the rest of the right hand side progressively thinner towards the top, so that flexing happens in a more distributed manner.
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK
RE: Which Material is Best? Am I Overlooking Something?
Hi Joan, I'm a long time reader of the forums and have seen and learned from your suggestions many times. I have begun some engineering changes similar to what you suggest which I think will certainly help things. But can you go more into detail about why the increased top and bottom layers are helpful compared to 100% infill? In my mind they are the same thing no?
Thanks
RE: Which Material is Best? Am I Overlooking Something?
Hi Mordtih,
I believe, most infills are now blocked from doing 100% infill within Prusa slicer, because the results are poor. the rectilinear pattern is the preferred infill for 100%
A long time ago I was playing with 100% infill and I Got issues with over extrusion/ poor layer bonding, which were cured with lots of top and bottom layers. so now I go straight to lots of top and bottom layers... Old habits... Lol
regards Joan
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK
Also experiment with sub 100% fill. 60% - 80% might give better results as the voids act as crack-stoppers and may permit a little more distortion before failure.
Cheerio,