How "Fine" can you print with PETG

I have been trying to print some prototype parts that include a fine screw thread. To make things more complicated, I have been trying to do this with a generic PETG filament. Over the past few days I have posted questions here and have made significant improvements to my test prints based on the feedback given and the article by “Donnie” over at themakersphere.com

My parts are almost where I want them to be and I have conducted both K-Value and flow rate calibrations, which added to the improvement.

But I am still getting fine pitch threads that bind once I have started screwing the top cap in place.

I’m just not sure whether I have reached the point where this is as good as I can expect to get (with PETG). I do not anything like this when trying the same prints with Generic PLA+ . The part will be attached to a motorbike, so I am going for PETG for it’s increased resistance to stress and damage.

Am I expecting too much from PETG?
Should I just start again with a less fine pitch thread?
Should I just accept that this as good as I can get?

Machine: P1S-Combo
Machine Firmware: 01.05.02
Bambu Studio Version: 1.9.1.66

Filament: Generic PETG Black

Nozzle: 0.4
Layer Height: 0.08
Flow Rate: 0.9405
Nozzle Temp: 255-265
Bed Temp: 80

To answer your question. There is no definitive answer to that because of the variations in filament and models. To get the answer you’re looking for, you’ll have to print and measure and then calibrate.

Just by eyeballing your print I can tell that you’re asking a lot of the technology. Your thread teeth are finer than the extruded 0.08 can produce. At the very least, you’ll find that the threads will tear away in a short time. Most 3D Printed Threaded items have very course threads. Not that what your asking for can’t be done, it’s just not very reliable the finer thread pitch you go.

Getting back on topic, as you probably know, the thing that will kill any material in your application is vibration. Vibration is insidious because it works over time; it’s not a go/no-go situation, so you usually don’t know that something is about to fail until it does so catastrophically.

A couple of things I might suggest. First, master the art of filament calibration. In particular, you will want to master X-Y hole-compensation and X-Y contour compensation in the slicer.

image

A great place to start is to take your CAD model and design two parts to fit inside one another. I’d recommend starting with a simple round cylinder and a round hole that should fit inside one another. No threads, just the two objects. Then take your calipers and/or feeler gauge and start printing and measuring what you sent to the printer versus what you measured. From there, you can offset the X-Y compensation to allow for each filament’s nuances and shrinkage. In case you didn’t know, hole compensation applies to anything that is enclosed, and contour applies to anything on the outside. The best way to visualize this in your slicer is to create two identical models and then, in the ‘object’ menu, change the compensation for one of them. When you slice it, the visual differences will be obvious, and you won’t even have to print. But it will give you a good feel for how the slicer’s algorithm works.

Identical objects after slicing with hole and contour compensation of 2mm and -2mm applied to the object on the right. The native object is a 25.4 x 25.4 x 0.20 mm cube primitive with a negative cylinder applied to it. You can see how dramatic the affect is.

Once you’ve figured that part out, you’ll be able to maintain fine control over your model. The downside is that you have to do this for each filament and the compensation is stored in the project, not the filament itself.

Once you’ve dialed in the closest calibration you can and the output resembles your design - it will never be perfect - then you can return to your threaded design and try out different thread pitch and or different filaments.

One tip. I use PETG and PC almost exclusively when making threaded parts. PLA just isn’t up the task, it’s too soft and pliable. PC is my preferred use for threaded items. Both for threads I have designed into the model and also for threads that I tap into the model using a simple steel tap. PC machines well because of it’s stiffness and hardness. However, it can also be brittle and depending on the filament, may not withstand UV exposure well. PETG is softer but if you make the threads course enough, it won’t matter and it stands up well to outdoor use as PC does.

If you don’t already have it, print out the bambu filament cheat sheet. https://cdn1.bambulab.com/filament/Bambu-Filament-Guide-EN.pdf

5 Likes

That’s a brilliant and very detailed reply. Thanks very much for taking the time put this together :clap:

I’m actually printing a tolerance test at the moment, but you have pointed out something I had not really considered and that, as you say, is pushing what the hardware can realistically be expected to achieve. It’s a great point.

I think the simple solution here is to print a less fine thread, it just has to be tight enough to hold a cap in place, and I can offset that with some sort of simple locking mechanism.

I also take your point about stress fracture risk due to vibration. I have printed parts for my bike previously and to date have reinforced the print in areas where this might be a concern. I particularly like using the “Variable Height Layer” tool in Bambu Studio to experiment with this.

Previously, I have found that if something is prone to failing, it presents itself while I am tightening a fixing in place. That can be a real drag when it happens, but at least it’s been tested to destruction.

Thanks again for taking the time to share your expertise. It’s very much appreciated.