Why Solid Areas Matter in Industrial Parts
Most 3D printed parts use internal infill patterns. These patterns save material and reduce print time. But some features need complete solidity for strength or function.
Threaded inserts, mounting points, and load-bearing surfaces often fail with standard infill. The solution? Force solid areas exactly where you need them. This CAD technique gives you control without changing your entire part’s density.
Additive manufacturing company Slant 3D recently shared this practical approach. It works across multiple CAD platforms and print technologies.
The CAD Technique Explained
The trick involves creating internal geometry that forces slicing software to fill areas completely. Here’s how it works in practice.
Create Internal Shells
Add thin internal walls or shells around areas needing solidity. These walls trick the slicer into treating the enclosed space differently. The software sees the geometry as requiring solid fill.
This method works because slicers apply solid layers to thin features automatically. By designing thin-walled internal chambers, you control exactly where density increases.
Practical Applications
Engineers should consider forcing solid areas in these scenarios:
- Heat-set insert locations for assembly points
- Threaded holes that need maximum pull-out strength
- Bearing surfaces under constant load
- Impact zones on protective housings
- Mounting bosses for fasteners
Benefits for Production Parts
This technique offers significant advantages for industrial applications. You get strength exactly where needed without wasting material elsewhere.
Production costs stay lower because most of the part uses standard infill. Only critical areas receive the extra density. This balance matters for cost-conscious manufacturing runs.
Design Considerations
When implementing this approach, keep these factors in mind:
- Wall thickness affects how slicers interpret your geometry
- Test different internal shell thicknesses for your specific slicer
- Document your approach for manufacturing repeatability
- Consider how orientation affects solid area placement
Understanding why orientation matters in 3D printing helps you position solid areas optimally. Layer direction affects strength in these critical zones.
Process Compatibility
This CAD approach works across multiple additive manufacturing technologies. FDM processes benefit most directly from this technique. But the concept applies elsewhere too.
With selective laser sintering, parts are typically fully dense anyway. However, designing for solid areas still matters for post-processing considerations.
Multi Jet Fusion technology also produces dense parts. The technique becomes more relevant when optimizing for weight reduction with hollow sections.
Implementation Tips
Start by identifying critical features in your design. Mark areas where failure would cause problems. These become candidates for forced solid geometry.
Create your internal shells at 1-2mm thickness initially. Test prints will reveal if adjustments are needed. Document what works for your specific material and process combination.
Working With Manufacturing Partners
When submitting parts for production, communicate your intent clearly. Note which areas require complete solidity. This helps manufacturing partners optimize their approach.
At JawsTec, engineers review part geometry before production begins. Clear design documentation speeds this process. You can request a quote with detailed specifications for best results.
Balancing Strength and Efficiency
The goal isn’t making everything solid. That wastes material and increases costs. Strategic solid areas provide strength where it matters most.
This design-for-additive approach separates professional applications from basic printing. Engineers who master these techniques create better, more cost-effective parts.
Understanding the strongest 3D printing materials helps you decide when solid areas are necessary. Sometimes material selection solves strength problems instead.
Moving Forward
Test this technique on your next project. Start with non-critical prototypes to learn how your CAD software and slicer interact. Build expertise before applying to production parts.
This simple CAD trick improves part performance significantly. It costs nothing extra in design time once mastered. The payoff shows in stronger, more reliable manufactured components.
Sources
Source: Force Solid Areas With This CAD Trick by Slant 3D (YouTube) — https://www.youtube.com/watch?v=CH0i818wz1o