This is my design of fully functional washers with built-in structural support. I created them for the FFF process to be printed using PETG or ASA material. Printed with the correct settings and materials, these washers are quite strong and can be used to spread the pressure of a screw head/nut evenly.
Dimensions and Tolerances
The file name and part number for the washers follow this format: LR2206-<thickness>-<inner diameter>-<outer diameter>.3mf
Thickness
The thickness is specified in tenths of millimetres. For example, 10 stands for one millimetre, and 22 stands for 2.2mm.
Inner Diameter
The inner diameter is specified with the metric thread size which fits into the given washer. The notation like M3 indicates the washer fits an M3 screw.
Outer Diameter
The outer diameter is specified in millimetres and represents the maximum outer diameter. The actual size is slightly smaller, allowing for the correct print profile.
About the Design
The weakest points in 3D printed parts are the binding points between print lines. Without optimization, a shearing force aligns with these printed rings of lines in a washer. By adding small channels, I print lines perpendicular to the ring, binding these rings much stronger. It effectively stops shearing forces at these layers, distributing them across all rings to prevent the inner sections from breaking loose.
