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3D Printer Tricks – Quick Threaded Holes

While working in the machine shop the other day, curiosity got the best of me. I was thinking abouthow to add fasteners to my printed part, but with a minimal amount of work. Fasteners can be drilled and tapped, Helicoil-ed, or ultrasonically welded into ABS parts. If the thread is large enough, it can even be modeled on the part directly, but what about smaller fasteners?
Typically, to create a threaded hole on a 3D Printed part, we would need to perform a few operations on another machine.  First, the part and the hole position would need to be located precisely, straight and true (“tramming and indicating”). Second, three tools need to be used: a center drill for the pilot hole, a tap drill of a specific size, and finally a tap. All these tools need to be used in the exact same location in order to generate an accurate screw thread profile. This is standard operating procedure with a CNC machine. However, you’re probably using a 3d printer to avoid the machine shop in the first place. You can save a few steps by inserting the tap drill size directly into the 3d print, with impressive results.

By printing parts with the tap holes already modeled in, we can eliminate several extra steps in the process, and the need of using a separate machine. Hand-tapping the precisely located holes is adequate for creating a functional thread.

The smallest thread in the test is marked, “4-40”, the tap hole is printed at .089”, and hand-tapped afterward.

The thread felt a little loose, indicating an oversize minor diameter. To remedy that, the tap hole can be made slightly undersize.  With a smaller tap hole, the slop wasn’t so dramatic of a concern on the larger threads (the largest here being 1/2-13).  Loose fit wasn’t a problem at all with the two tapered threads in the upper left hand side, a 1/8-27 NPT and 1/4-18 NPT.

By printing the tap holes directly into the part, we avoid several steps typically needed to insert threads into 3d printed parts, only needing threading.  All of these threads were created with a hand tap, and as long as the tap goes in relatively straight, it produces quality threads without all the usual effort.

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Note * Copied from  Chris Lopez (Goengineer's bolg)

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3D Printing

3D Printing - It’s one thing to have an idea in your head — it’s something else to hold it in your hands. Take your 3D CAD designs from on-screen to in-hand with realistic 3D models. Test form, fit and function. Print assembly tools on the fly or manufacture small quantities of production parts.

It’s all possible with3D printers, think faster. Move quickly. Cut costs.

Additive manufacturing or 3D printing is a process of making a three-dimensional solid object of virtually any shape from a digital model. 3D printing is achieved using anadditive process, where successive layers of material are laid down in different shapes.

The 3D printing technology is used for both prototyping and distributed manufacturing.

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How to Design a Boat Hull in SolidWorks Free Form Demo

This Demonstration exhibits the New Free From Feature in SolidWorks 3D CAD Software.Learn how to create a Boat Hull from a sketch drawing using the SolidWorks Sketch Picture Feature.

About SolidWorks

A prototype is an early sample, model or release of a product built to test a concept or process or to act as a thing to be replicated or learned from. A prototype is designed to test and trial a new design to enhance precision by system analysts and users. Prototyping serves to provide specifications for a real, working system rather than a theoretical one.

Design and modeling

In many fields, there is great uncertainty as to whether a new design will actually do what is desired. New designs often have unexpected problems. A prototype is often used as part of the product design process to allow engineers and designers the ability to explore design alternatives, test theories and confirm performance prior to starting production of a new product. Engineers use their experience to tailor the prototype according to the specific unknowns still present in the intended design.

Prototypes are used to confirm and verify consumer interest in a proposed design whereas prototypes will also attempt to verify the performance or suitability of a specific design approach.

Differences between a prototype and a production design

Prototypes will differ from the final production variant in three fundamental ways:

Materials. Production materials may require manufacturing processes involving higher capital costs than what is practical for prototyping. Instead, engineers or prototyping specialists will attempt to substitute materials with properties that simulate the intended final material.

Processes. Often expensive and time consuming unique tooling is required to fabricate a custom design. Prototypes will often compromise by using more variable processes,

repeatable or controlled methods; substandard, inefficient, or substandard technology sources; or insufficient testing for technology maturity.

Lower fidelity. Final production designs often require extensive effort to capture high volume manufacturing detail. Often prototypes are built using very limited engineering detail as compared to final production intent, which often uses statistical process controls and rigorous testing.