Strengthening a 3D Printed Part

As we all know, 3D printed parts produced by our ordinary home type printers are not so strong and when used in place of actual parts, they don't last long. I thought it would be great If it is possible to somehow strengthen the 3d printed parts and worked on the subject a bit.

Strengthening a 3d part may give us the ability to use those parts in place of actual working, load bearing parts. So instead of trying to find an original replacement part for a broken one of our gadgets, robots, vehicles, mechanical toys or in any mechanical tech project we develop, we can simply go with the 3d printed parts.

The need for me to develop this instructable arose in fact when i bought some bicycle accesories from ebay. Recently I've bought two cycling front pannier bags . One for my gf's bike and one for mine. The bag's support was suitable for 1" handlebar thickness and barely fitted to my gf's bike. And didn't fit to mine as my bike had a 31.5mm thick handlebar.

I planned to manufacture the parts with matching dimensions to my handlebar by 3d printing them.

Step 1: The Part Required

This is the disassembled part which I planned to produce by 3d printing.

To produce a 3d printed part, you need to have the 3d model files for it. So you need to either find and download them from the internet or get to work and model it yourself. Way 2 was the only choice I have, as 3d model for a specific part like this is impossible to find on the internet and I needed to modify it to fit my handlebar anyway.

But as very well known, 3d printed parts are not so famous with their strength. I've thought that an ordinary printed part willl not be strong enough to work properly at my bike, with heavy stuff in the bag, going on bouncy roads. So I thought that it will be necessary to strengthen the part somehow.

In my previous boatbuilding experience several years ago, I saw how much some layers of fiberglass and epoxy give extra strength to a thin plywood part, enabling it to withstand strong forces easily.

So I decided to use fiberglass and epoxy to do the job.

First plan was to model the part, do the necessary modifications on the dimensions and cover all around it with fiberglass fabric and epoxy. So I started modeling my first design for the part.

Step 2: The First Design

I ended up with a part like this. I've arranged necessary details with required dimensions, and overall enlarged other dimensions to make it a bit bulkier. I've enlarged the surfaces for them to be able to carry reinforcing fiberglass fabric.

I also made grooves on all sides for the epoxy resin to fill and give the part an extra strength. I've modeled holes that go through the part from one side to the other, to connect the sides together internally, provide a link with fiberglass and epoxy to support from the inside.

I've printed the part using an Up printer and tested whether it fits to other original parts.

I choose a lattice type fill while printing leaving quite emty space in the printed part. This normally should reduce the strength of the part considerably but it was done for a purpose. I've drilled several more holes on the printed part, between the 3d modeled ones for the epoxy resin to flow inside part, giving the part much greater strength.

Step 3: Applying Fiberglass and Epoxy to the First Design

This is the dirtiest part of the job. Epoxy and fiberglass is hard to work with. Sticks to everything and very difficult to clean.

First I took several fiberglass threads from the fabric and sew the parts from one side to the other to provide a glassfiber reinforced connection between the sides.

Then I laid the parts on a piece of nylon as epoxy fortunately doesn't stick to nylon well. Then applied epoxy resin to the surface, put the fiberglass fabric cut to required shape and size over the wet surface and applied more epoxy on top. Until the fiberglass fabric becomes transparent.

Repeated this for each side on all parts and left them to cure around a day after each application. Took a while for the parts to be glassed completely.

Step 4: More Epoxy for Added Strength at the Sides

I've poured some more epoxy to the side grooves of the part for sideways strength.

Step 5: The Second Design

While making the first design, the idea was to partially fill the inside of the part with epoxy thru the extra holes drilled strengthening it from the outside by covering it with epoxy soaked fiberglass. While printing the first part, this second thought came to my mind to 3d model the part as a bare shell only and build the inside structure with epoxy and fiberglass later on.

So I started modeling this while also still waiting for the layers of epoxy-fiber to cure over the first one. I wanted to manufacture both designs and compare them in strength and ease of production. I also used different approaches towards filling the part 1 and 2 of the second design( two parts were necessary for mounting the bag to the bike).

As seen, the second design is an empy shell with 1mm wall thickness. The round part is separated from the big part to make the filling process easier. It is possible to screw fit the round part back to the main part during the curing of the epoxy fill inside.

Step 6: Filling the Second Design With Epoxy and Fiberglass

First I shredded some amount of fiberglass and stuffed them into both of the parts until they are more than half full. Then started pouring small drops onto them and applying a bit of pressure to soak them.

Step 7: More Filling Into the Design#2 Part#1

Continued this until all fabric inside is wet and then added more fabric and epoxy step by step making the inside of the part is full. Then Screwed the round part on top of it. I continued filling the part, rising the level of epoxy-fiber mixture to the edge.

I did the same to the smaller part.

Step 8: Filling the Second Design's Part 2

For this part, I followed a little bit different approach, I didn't fill it to half full from the start. I've placed only one layer to the bottom of it, than a second layer covering both the bottom and also the sides. Wetted these two layers with epoxy until they are completely transparent and continued adding layers one by one and appying pressure to get them wet with epoxy. Added a bit more epoxy for every 2-3 layers.

With the previous mehod, the part was filled with more epoxy and a little bit less fiberglass fabric. With this method, the part is filled with a lot of fiberglass and less epoxy in between the layers.

Step 9: Left All the Parts to Cure.

I checked all the parts from time to time and filled the spaces which were formed due to epoxy flowing inside the gaps. Added more fiberglass fabric where necessary. Time for the parts to completely cure and harden is around a day. There are faster epoxies on the market or you can add the hardener more than necessary to speed up the process but I don't recommend as it gets even more difficult to work and disables the epoxy to flow inside and fill the empty spaces.

Step 10: Completed Parts and the Assembly

Well the completed parts turned out to be rather nice, especially with the second design. I assembled them along with the existing parts of the pannier. They matched perfectly. Ready to be mounted on the bicycle.

Step 11: Removing the Plastic Parts

This step was not intended to be done in fact. I was planning to use the 3d printed parts with the reinforcing inside them. But while I sanded one of them, the printed skin at the outside of one corner just broke off and the rest peeled off very easily. As it provided no extra strength to the part, I removed nearly all of it, converting the part into an epoxy-fiberglass composite part.

Step 12: Results

I've used the parts during a 20 days trip around Sweden, Poland, Germany and Denmark without problems. The front bag was absolutely full with food during the whole trip and there were a lot of bumpy roads in the path too. The parts worked great and they are still rock solid. I've listed some results from this study below.

1-Interestingly, epoxy doesn't stick to 3d printed ABS plastic well. So extra holes and negative details that provide holding points for the cured epoxy is mandatory.

2- Covering a 3d printed part is much difficult than simply filling an empty part. It takes a lot of time. In the end this produces a lighter part. And there is certainly a great strength improvement over a 3d printed part without reinforcement. It is easy to see this, comparing a reinforced and non reinforced parts by simply trying to twist them by hand. The reinforced part is absolutely rock solid while the other is not.

3- The second method of reinforcing is much easier and produces a much neater result. There is nearly no need for cleaning after curing. And the produced part is like granite. :)

4- I've tried two approaches with different amounts of fiberglass, when handled, they both give the same feeling for strength and solidity. But the one with more fiberglass should be able to bear more weight before breaking I strongly guess.

5- The second design produces a heavier part, as it is completely full with epoxy and fiberglass. Removing the abs plastic parts surrounding the epoxy reduced some weight. But it also changes dimensions of the completed part. So dimensions must be adjusted during design, taking into the change the lack of abs plastic will bring.

6-Grooves and empty spaces can also be put into the design of the second part to prevent epoxy to fill into them, thus creating a lighter part.

Comments

[jpfalt]

I have been using 3D printed ABS parts since about 1994 and made functional parts for landscaping equipment. I found three methods that vastly improve the performance of the material.

1. The first is to do a 10 second dip in acetone. The ABS equals nylon in strength in the x and y directions, but the z direction is about half strength, like plywood. The acetone dip fuses the individual abs strands into a solid and increases the z direction to full strength. This also has the effect of making the part water and air tight by sealing together the pores in the deposite strands of abs.

2. On rotary ad hoop parts, I leave a groove and drill small holes if required and wrap the part with two wraps of .041 horrible fright stainless steel lock wire with a twisted end using lockwire pliers and clipping to leave about two full twists. I made a series of backpack blower impeller fans up to 8" diameter that successfully ran for extended testing at 8500 rpm.

3. Fiberglass or epoxy reinforcement can be applied directly to the ABS by painting the surface with acetone and laying on the fibers. I have also wrapped the fibers and then painted with acetone to melt the ABS underneath to capture the fibers. Finally, I keep a bottle of ABS dissolved in acetone to paint over fibers ir metal inserts. The acetone fully evaporates overnight and leaves full strength ABS over the top of the .reinforcement.

A final method that I don't count is to make a metal part and 3D print a wrapper. I did this for a bakelite reversing handle on a large disc sander. The original got smashed during a machine move and the replacement used an original metal core and printed two parts that were assembled around the core and fused with acetone.

I found three different things that really

[AdamG84]

I'm trying to strengthen a part I'm building and I'm making it out of ASA have you used this material in place of ABS? I've heard the two have very similar properties. ASA just has better resistance to UV degradation.

[jpfalt]

I have not used ASA, however, you want to treat it with a solvent that will dissolve the plastic and re-harden to the original plastic after it evaporates. Charts I have reviewed indicate that acetone should work as a fuser on ASA, but Wikipedia indicates there are some other solvents that can be used to glue ASA. One of these should work well to fuse the printing or to fuse reinforcing fiber into the surface of the part.

[DaoD1]

I am considering doing your method 1 then coating it with method 3 with my 3d printed part. Is it possible to do so?

[jpfalt]

If I'm doing reinforced parts I use both methods 1 and 3 on the same part. Method 1 makes the ABS uniform strength in all directions and method 3 adds additional strength in whatever dimension the fiber strands run.

Something I will do in addition if I want a smoother surface after fiberglass or kevlar reinforcement is to pain the part with ABS dissolved in acetone to build an additional layer of plastic for sanding and finishing. I use a small glass jar about 2/3 full of acetone and add the ABS printing filament until the solution starts to thicken. Then I just paint it over the surface and it fuses to the part.

[DaoD1]

Thank you very much! I will try to see how much stronger my part improves.

I am doing a project at school that is using post treatment to make my 3d printed tensile bar the strongest. I looked everywhere on the internet and came across your comment. Thanks a lot for sharing!

[puneethrj]

This is indeed useful. This deserve to be an instructable rather than a comment.

[hobbyman]

This is very valuable information, thanks for sharing it with us.

[GarethB28]

SO it seems to me that the best way of amking parts is to print a 3D mould. You can then just peel away the 3D ABS/PLA and you are left with a structural fibreglass product with tight tolerances. Very useful article and thanks for sharing.

[MsAlvigo.]

Brilliant idea, thank you !

[smrat alleck]

Thanks for sharing; this is a clever idea that I could see being useful in many situations. Glad it held up for your bike tour!

[JON-A-TRON]

Great idea! I bet this part is rock-solid.

[pkrueger]

I have thought of just using them to make sand castings....

[drinkypoo]

All I want for christmas is a 3d printer that can print me molds for lost wax casting. I haven't been able to find any inexpensive printers/extruders which claim to be able to do the job.

[spaceman874]

i have used PLA to do that. it works. the temps are just a bit higher and it takes a bit longer for the PLA to have evaporated. works a treat :)

[GergelyD]

Nice job, I'd like to add some ideas you may find useful.

I'm
working as a propmaker for the film industry, therefore usually all I
make are 'prototypes' within a very tight timeframe. Some of them must be strong some of them just
nice.

I rarely use 3D printing since the process is still unacceptably slow.

But
sometimes I make layered slosh casts (in a silicone mold) for the nice
surface which is reinforced from the inside (regarding a one sided
mold). For this I use the smoothest possible glass matting (like silk)
with epoxy resin and fill the rest with micro-fibre filled Polyurethane
resin.

In your case I'd use Polyesther resin since it bonds to ABS
(since Polyesther's and ABS' main agent is Styrene), and or the
Polyurethane casting resin mentioned above. Sensitizing the ABS surface
with Acetone is well tested method too like an other commenter wrote.

Otherwise
I'd cast a block from the same material and mill the piece out on my
CNC. Since you have to make the 3D model first on your computer all you
could gain with this method is time and surface finish quality. After
having the first piece made, I'd mould it in silicone and cast as many
pieces later I'd need...

I buy my stuff from PS-Composites if anyone care.

[moein]

why you dont try cnc milling instead of all these hard work ? !

there are tons of parts and designs that can simply be made with machining and milling.

i am a fan of 3d printing but i think earlier methods still work nice in many cases. you have spent hours and and used various materials in a time and energy consuming way. as i see the part has a rather simple design that can be done by any cnc machining. you may say cnc milling machines are way more expensive than domestic 3d printers and a few people may have access to them. but as i can tell you a domestic low power cnc milling machine can to this nicely. plus working with fiberglass and resin is not that simple and needs some facilities. a benefit of 3d printing vs milling and machining is its elegance and ability to print complicated shapes and volumes. if i want to add fiber glass to my designs after i printed it, i am limited to simple and crude shapes and all 3d printing benefits will be eliminated.

i think you are just trying too emphasis on including 3d printer in your projects because it is cool maybe. otherwise there are far better solutions for this issue that do not need a 3d printer.

[hobbyman]

you are absolutely right. We have two 3d printers and and two CNC milling machines of different sizes at school. Hired a mechanical engineer to be able to run the CNC machines last year. He worked for a full month just to mill a part with CNC, there were big problems with the machines. He managed to fix the problems of the small one(size of a 4 person table) and gave up working on the big one (triple the size) saying that it had an inherent design flaw. Later the firm we bought the machine from also said the same thing and proposed a method to fix the problem that costs several thousand dollars. Well, it is a bit difficult to arrange funds so it is still broken. But 3D printers are easy. we just click print, and they print. Would have loved to use the CNCs as well but as i've said. they are much more difficult to operate.

[jjsorensen]

Another option would be to make an epoxy cast. These kits go for about $50 at Hobby Lobby. You could have skipped all the modeling work entirely.

Rule 34 applies to a lot of small parts like this. Your local bike shop probably has a box of these. Mine usually just gives me stuff like this.

That being said, this is an awesome way to create a epoxy cast for something you don't have other resources for. A thin-walled mold would be pretty cheap and quick to print. Thanks for the info.

[hobbyman]

thanks for the info, didn't hear that before could you give a link for a sample epoxy cast?