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[3D Printing News] Structure Design Collection: Make Your Product More Flexible! (Part 1)

【3D Printing News】A Collection of Structural Designs to Make Your Product More Flexible! (Part 1)

Our convenient daily lives are actually filled with tools or components with complex functions. From small staplers to large cars and motorcycles, if a single assembly is taken apart, each component needs a "connecting structure" to link them together. This time, we will introduce several common connecting structures and design principles to provide you with more methods for product design.
 

We can first divide these structures into two types of connection: "permanent" and "reusable". If the components do not need to be disassembled after assembly, a "permanent" connection structure is more stable. Conversely, if it needs to be used for features like snap-fits, opening and closing mechanisms, or requires disassembly for testing other combinations, a reusable structure should be chosen.

This time, we will first introduce several common permanent connection structures: non-disassemblable after assembly, stable and durable:
 
1. Snap-fit
Suitable for designs where internal product space is minimal, or the appearance tends to be streamlined, such as enclosed casings, etc. After snapping together, there are no protruding components, which can reduce the risk of accidental disassembly of the product.
 

 

 

2. Sleeve + Barb
The design principle utilizes the open elastic tab design of the sleeve to generate a slight tension allowing the barb to pass through, and then uses the barb to hook the sleeve in reverse. Since the connection point is internal and completely covered by the component's casing, the object will be very secure and stable if the gap is designed correctly.








3. Self-locking Snap-fit
Another commonly used structure and the sleeve combination above is based on the concept of male and female reversal, where the snap-fit is redesigned with an open design and slightly bent outwards. It narrows during assembly and then expands again once in position to secure the object.
 

 

 
4. Expansion Bolt
Compared to the previous image, the difference in this design is that the expansion bolt is separate from the relative component. The advantage is that after assembling the parts, the screw can still be individually removed by drilling or disassembling. Plastic injection molding is a common method for mass production, but SLS 3D printing technology can not only understand product shapes during the development phase but also be directly used for testing more complex functional components, as Sinterit's laser powder technology places almost no restrictions on the structure of prototype samples. (What is SLS 3D printing technology? Beginner's guide: Comparison and Principles of Common 3D Printing Technologies)
 





Traditional assembly structures could be put together with adhesive, nails, or screws, but this might damage the product casing or aesthetics, or be unsuitable for prototyping due to prototype damage. The structures introduced in this article can all be printed in a single pass using SLS technology with Sinterit Lisa and Lisa PRO 3D printers. They are aesthetically pleasing and functionally stable, providing more practical inspiration for product designers.

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