Add Fillet Radii to Reduce Stress Concentrations

Sharp internal corners create stress concentrations that can cause cracks and failures. Adding a fillet radius distributes load over a larger area, significantly reducing peak stress. This is one of the simplest and most effective ways to reinforce weak points.

For 3D printed parts, a radius of at least 0.5mm helps, but larger is better. For machined parts, aim for a radius no smaller than one-eighth of the adjacent wall thickness. If the design allows, use a radius equal to the wall thickness for maximum strength.

A case study: a bracket with a 90-degree internal corner failed after 10,000 cycles. Adding a 3mm radius increased fatigue life to over 100,000 cycles without changing the overall geometry. The fix took seconds in CAD but multiplied part longevity.

Before reinforcing with ribs or thicker walls, always add fillets. They cost nothing to implement and can turn a marginal design into a durable one. Start by checking every internal corner in your parts.

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