Solutions for 3D Printed Spring: Tips for Successful Manufacturing

Springs are essential components in mechanical applications, with functions such as force resistance, vibration reduction, and energy storage. With the advent of 3D printing, certain techniques and considerations are essential to making durable and practical springs due to the layer-by-layer manufacturing nature of 3D printing. In this article, we will introduce tips for successfully designing and printing various types of springs.

3D Printed Spring Types

Due to the material and structural limitations of the process, not all types are feasible. Here are some of the most effective 3D printed spring designs:

Extension Springs: Ideal for providing resistance, such as in buttons or switches. These springs can be printed in a flat, zigzag pattern to optimize strength.

Stabilizing Rings: These multi-directional springs combine flexibility and resistance, making them ideal for mounting or vibration isolation.

Leaf Springs: Used for stabilization and vibration reduction, leaf springs can be designed as flat, flexible plates or complex geometries for tight control.

Spiral Springs: Ideal for energy storage in applications such as wind-up toys or lid mechanisms. Their compact and dense design makes them a versatile choice.

Source: Slant 3D, https://www.youtube.com/watch?v=wpriGP45Unw

Tips for designing 3d printed springs

Designing springs for 3D printing requires careful attention to geometry, material properties, and stress distribution. Follow these tips for best results:

Printing orientation: Always design springs to print in the same plane as the layer lines to maximize strength. Printing springs at an angle or vertically places forces perpendicular to the layer lines, increasing the likelihood of breakage.

Rounded edges: Sharp corners can cause stress concentrations, which can weaken the spring. Rounded edges ensure smoother force distribution and better resilience. For spiral or flat springs, you can add "chamfers" or "fillets" with modeling tools such as Fusion 360 or SolidWorks.

Adjusting thickness: Increase thickness for a stiffer, stronger spring, but also avoid too long a single thickness spring, which can result in excessive stiffness and loss of elastic properties. For springs that require more travel or are more flexible, thickness can be reduced to 1 mm or less, but designs that are too thin may increase the risk of breakage.

Customizing with patterns: Adding custom "slots" or "openings" to a extension spring can control the range of deformation of the spring when stretched. For example, evenly distributed rectangular grooves provide stable tensile properties.

The stiffness of a spiral spring can be changed by adjusting the pitch of the helix - a wider pitch provides a larger range of extension and contraction, while a narrower pitch provides a higher stiffness.

Material selection for 3D printed springs

The selected material is an important step in creating a perfect 3D printed spring.

PLA is suitable for low-stress applications and prototyping.

PETG is stronger than PLA and is suitable for low to medium stress applications.

ABS is suitable for springs subjected to mechanical or thermal stress, such as robotics or appliance parts.

Nylon is often used in springs in sports equipment and medical devices due to its high toughness.

TPU and TPE are extremely flexible, but difficult to print.

For applications involving repeated stress, make sure the material's stress-strain behavior is within the elastic range to avoid permanent deformation.

Source: https://www.printables.com/model/534644-spring-material-test

A major advantage of 3D printing is that it can meet the manufacturing needs of "unconventional style springs". If you need professional 3D printing services, JLC3DP provides you with a wealth of material options and high-precision printing technology to meet various spring design and application needs.