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Adding Heated Inserts and Other Components to 3D Printed Parts

Integrating components like heated inserts, metal inserts, or embedded electronics into 3D printed parts can significantly enhance their functionality, durability, and assembly options. Whether you’re a hobbyist or an industrial designer, understanding how to incorporate these elements into your 3D printed projects can expand what’s possible with additive manufacturing. In this guide, we’ll explore the different types of inserts, how to install them, and best practices for integrating other components.

Why Add Inserts and Components to 3D Printed Parts?

3D printed parts can be designed to be lightweight, complex, and customizable. However, sometimes they lack the strength, durability, or specific functions required for certain applications. By adding inserts and components, you can:

  • Increase strength: Heated inserts and metal components can add mechanical strength to high-stress areas, like mounting points or joints.

  • Enable assembly: Inserts allow 3D printed parts to be connected to other components through screws or bolts, making them more versatile.

  • Integrate functions: Embedded electronics, wiring, or sensors can turn a simple 3D printed part into a functional device.

What Are Heated Inserts?

Heated inserts, also known as heat-set inserts, are metal components that can be embedded into 3D printed parts to create strong, threaded connections. They are often made of brass and have external knurls or ridges that help them securely grip the 3D printed material when heated and pressed into place.

Benefits of Heated Inserts

  • Improved Thread Strength: They provide stronger threads than directly tapping threads into plastic, making them ideal for assemblies that need to be repeatedly screwed and unscrewed.

  • Durability: The metal insert distributes the load across a wider area, reducing the likelihood of the 3D printed part cracking or deforming.

  • Heat Resistance: Heated inserts can withstand higher temperatures than the 3D printed material itself, making them suitable for applications that involve heat or friction.


How to Install Heated Inserts into 3D Printed Parts

1. Prepare the Part

Design the 3D printed part with holes sized for the inserts. The holes should match the outer diameter of the insert to ensure a snug fit. You can find recommended hole sizes from insert manufacturers or design software guides.

2. Gather Your Tools

To install heated inserts, you’ll need:

  • Soldering iron with an interchangeable tip or a heat-set insert tool

  • The heated inserts (typically brass)

  • Tweezers or pliers for positioning

3. Heat and Insert

Place the heated insert over the hole in the 3D printed part. Using the soldering iron, press down gently on the insert until it melts into the hole. Allow the plastic to flow around the knurls of the insert, then remove the soldering iron and let the part cool. The insert will be firmly embedded in the part, creating a durable threaded connection.

4. Check Alignment

Once the insert is installed, check the alignment by screwing a bolt or screw into the insert. Ensure that it is straight and secure, without any wobbling.

Other Inserts for 3D Printed Parts

Beyond heated inserts, there are other options for adding threaded connections or strengthening 3D printed parts:

  1. Press-Fit Inserts: These are designed to be pressed into undersized holes in 3D printed parts. They rely on friction to stay in place and are ideal for quick installations without the need for heat.

  2. Ultrasonic Inserts: Similar to heated inserts, these are installed using ultrasonic vibrations that soften the plastic, allowing the insert to be pressed into the part. They provide strong and reliable connections, often used in high-performance applications.

  3. Helicoil Inserts: For applications that need even stronger threads, Helicoil inserts (coiled wire inserts) can be embedded into 3D printed parts. These inserts create durable threads that resist wear and tear, especially in high-stress environments.

Embedding Other Components into 3D Printed Parts

3D printed parts can also be designed to accommodate non-threaded components like magnets, bearings, electronics, and wiring. Here’s how you can integrate some of these elements:

1. Magnets

Magnets can be added to 3D printed parts to create closures, attach parts, or add functionality. To do this, you can design a slot or cavity in the 3D model where the magnet will fit. Use epoxy or superglue to hold the magnet in place after printing.

2. Bearings

Bearings are used to create smooth rotational movement in 3D printed assemblies. To integrate a bearing, design a snug, round recess in the 3D model. Ensure that the bearing fits tightly in the recess, possibly requiring a press-fit.

3. Electronics and Wiring

For electronics like sensors, LEDs, or small PCBs, you can design channels or pockets within the 3D model. This keeps wiring neat and ensures that the components are properly secured. To add electronics:

  • Plan wiring channels in the design phase to avoid post-processing adjustments.

  • Use hot glue or silicone to secure electronics within the printed part.

Best Practices for Integrating Components

  1. Design with Tolerances in Mind: When designing parts to include inserts or components, factor in clearance and tolerances. Inserts require snug fits, while electronic components may need slightly larger cavities to accommodate wires or solder joints.

  2. Choose the Right Material: For 3D printed parts that will hold inserts or components, opt for stronger materials like Nylon, PETG, or ABS. These materials have better mechanical properties and can handle the stresses of inserting components.

  3. Test Before Final Assembly: Before committing to a large print, create a small test part to ensure that the insert or component fits properly and functions as intended. This can save time and material costs.

  4. Use Reinforcement: For parts that will undergo high stress, consider reinforcing the design with thicker walls, ribs, or additional layers to provide extra strength around the embedded component.

Adding heated inserts and other components to 3D printed parts opens up a world of possibilities, allowing you to create stronger, more functional, and versatile designs. Whether you’re building prototypes, manufacturing end-use parts, or developing custom assemblies, integrating components like inserts, bearings, or electronics can enhance the performance and longevity of your 3D printed creations.

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