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How to add threads to SLS 3D printed parts
Adding threads to SLS 3D printed parts is a critical consideration when moving from concept models to functional prototypes or production-ready components. The method you choose – whether tapping, inserts, or printed threads – directly impacts part performance, longevity, and assembly ease. By understanding the strengths and limitations of each approach, you can ensure your parts deliver the durability and usability required for real-world applications.
Technical rundown
- Tap after print
You can tap internal threads into SLS parts using your CAD-designed holes or post-print drilling. SLS parts printed in Matrix PA12 CR are strong enough for this, offering high strength, stiffness and long-term dimensional stability. - Use threaded inserts
For repeated assembly or load-bearing situations, brass or helicoil inserts are best. We can fit threaded inserts into SLS parts as part of secondary assembly operations. - Printed threads
Modelling threads directly in SLS is possible but often unreliable for fine features due to resolution limitations. Reserve this for low stakes prototyping rather than functional use. - Design tips
Ensure ample wall thickness – extra material around holes helps prevent cracking during tapping. Whenever possible, orient parts to minimise unsupported overhangs for stronger thread integrity. - Post-processing impact
Finishes like lacquering, dyeing, bead-blasting or RFI/EMC treatments can change friction or clearances internally. We offer these finishing options and also blackouts for functional parts. Always check how your post-processing might affect threaded features.
Why this matters for functional parts
- Robustness: Inserts dramatically improve wear resistance and longevity compared to plastic threads.
- Reusability: Printed threads fail quickly under repeated use. Inserts preserve service life.
- Speed vs function: Tapping is quick and effective for moderate loads. Inserts deliver reliability for functional assemblies. Printed threads are for rapid mock-ups only.
Our in-house SLS capabilities
Material: Our SLS parts are produced in Matrix PA12 CR, a high-performance nylon powder with excellent strength, stiffness and abrasion resistance. It offers long-term stability, is biocompatible and approved for food contact. Compared to PA 2200, it delivers the same functional performance while reducing the CO₂e footprint by around 45%.
Machines & size: We run EOS Formiga P1 with build volumes including 220 × 250 × 330 mm.
Finishing & assembly: After printing and cleaning, we offer lacquer sealing, dyeing, vapour smoothing, bead-blasting, blackout/RFI coatings and assembly actions including insertion of threaded inserts.
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