On 10/13/21 12:02 AM, John Dammeyer wrote:
Chrome plated pot metal and if that can crack and break a 3D printed handle would definitely.
An FDM 3D printed crank arm would almost certainly break, regardless of the material used.
An MSLA (resin) 3D printed crank arm almost certainly would not break. I would fix this problem by creating the part in FreeCAD and printing it on a resin 3D printer using an "ABS-like" structural resin.
A part's strength can be measured in many ways, but in general, MSLA resin printed 3D parts created using a structural polyurethane resin are stronger than aluminum but not as strong as steel. The polyurethane is as durable as a hockey puck and polyurethane is very resistant to cracking, unlike aluminum or the pot metal original part.
Even for home gamers, 3D printers are not just filament based. Resin goo MSLA 3D printers are now fairly cheap, and the resolution is almost as good as injection molding. The parts are very strong and the material cost is around US$.03 per gram. Part strength is isotropic so layer delamination isn't a problem when designing parts as it is with FDM 3D printing. The biggest MSLA downside is the isopropyl alcohol part cleaning and UV post curing, but it's not that bad.
Someone needs to make an upgraded MSLA printer that automates the post processing operations.
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