Contents

Preview: this cheatsheet is still in development and the content hasn't been independently verified.

Designing real parts20 / 31

Sizes that print well

Pick sizes that the printed plastic can actually hold. These are the defaults seasoned makers reach for.

Fasteners: M5 and up

Fasteners: M5 and up

M5 is the smallest size that grips printed plastic reliably. M6 for everyday brackets, M8 / M10 for load-bearing joints. M3 strips out at the first over-tighten, so skip it unless you're using a heat-set insert.

Heat-set inserts: M5 / M6

Heat-set inserts: M5 / M6

Brass insert melts into a printed boss and provides the threads. Design the boss at 8.5mm OD for M5, 10mm for M6. Thinner walls split when the insert melts in.

Linear motion: 8mm rod

Linear motion: 8mm rod

LM8UU bearings, 8mm chromed rod. The whole ecosystem assumes this size: couplers, brackets, leadscrews all line up.

Bearings: 608 (8 × 22 × 7)

Bearings: 608 (8 × 22 × 7)

Cheap, plentiful, prints into a 22mm pocket with a 0.2mm interference fit. 624 / 625 work too; below 4mm bore is fragile.

Knuckle hinge: 4mm × 1.75mm

Knuckle hinge: 4mm × 1.75mm

4mm knuckle around a 1.75mm steel pin (offcut of filament works). BOSL2's knuckle_hinge() defaults. Smaller knuckles split; bigger waste plastic.

Frame stock: 2020

Frame stock: 2020

20 × 20mm aluminium extrusion with a 6mm T-slot. M5 T-nuts drop straight in. 3030 if you need more rigidity.

Belt: GT2 6mm

Belt: GT2 6mm

2mm pitch, 6mm wide. 16T or 20T pulleys on a 5mm shaft. Everything heavier than a print head wants 9mm width.

Snap pin: 7 × 11mm

Snap pin: 7 × 11mm

7mm head, 11mm long total. The push-and-click connector between two printed parts. Replaces a screw on light-duty joints. Below a 5mm head the petals get fragile; above 10mm it's a screw waiting to happen.

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