Reinforce Weak Points: Fillets, Gussets, and Orientation

Sharp internal corners are the most common weak point in printed and machined parts. They act as stress concentrators where cracks start under load. The simplest fix is to add a radius or chamfer to every inside corner. In machining, specify a fillet radius equal to your cutter's corner radius. In CAD, use the fillet tool before exporting.

For parts that bend or flex, add gussets or ribs at the junction. A triangular gusset transfers load from a wall to a flange, increasing stiffness dramatically. Keep rib thickness no more than 60 percent of the adjacent wall to avoid sink marks in plastic parts.

In additive manufacturing, remember that parts are weaker along the build direction. If a feature is load-bearing, orient the print so layers are perpendicular to the stress. Some printers allow continuous fiber reinforcement along specific toolpaths, which is the strongest option.

Check your design by applying load in simulation or by destructive testing a prototype. Even a small radius or rib can double the part's fatigue life. These fixes cost nothing in CAD and maybe a few minutes of machine time, making them the quickest upgrade you can do.

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