Weak corners and thin walls usually come from orientation, insufficient walls, poor layer bonding or stress concentration. Increasing infill may not solve the failure.
Inspect failure
- Corner crack.
- Layer separation.
- Thin-wall buckling.
- Load direction.
Improve design
Increase wall count, add radii and ribs, and align layers with the load. Move fastener loads away from thin edges.
Validate
- Bend test.
- Real load.
- Fracture surface.
| Cause | Action | Check |
|---|---|---|
| Sharp corner | Add radius | Stress |
| Thin wall | More walls | Bending |
| Layer direction | Reorient | Adhesion |
| Low temperature | Increase within range | Bonding |
Common engineering mistakes
- Only adding infill.
- Ignoring orientation.
- Leaving sharp corners.
- Testing a coupon only.
- Using wet filament.
Buyer checklist
- Where does it fail?
- What is the load direction?
- Are walls sufficient?
- Are corners rounded?
- Is failure repeatable?
Send geometry and failure photos through our quote form.