PrintGig

We just completed a PEKK print job — and it's one of those materials that makes you appreciate how far 3D printing has come.

So what makes PEKK special?

→ Glass transition temp of 162°C — stays rigid where most polymers fail
→ Continuous use up to 260°C
→ Inherently flame resistant (UL94 V-0)
→ Outstanding chemical resistance
→ Trusted in aerospace, oil & gas, and defence applications

It sits at the very top of the polymer performance pyramid — the kind of material you reach for when failure simply isn't an option.

If you're working on parts that need to survive extreme heat, harsh chemicals, or demanding environments — PEKK is worth knowing about.

Clearance in 3D printing is not the same as in CNC

A lot of people copy CNC-style fits directly into 3D printing.
On screen, 0‑gap looks perfect.
In reality, it usually means parts that won’t fit.

Fact is:

CNC can hold something like 0.01–0.05 mm tolerance
thanks to rigid setups, precise tooling, and stable machining.

3D printing is usually in the 0.1–0.5 mm range,
depending on process, material, layer height, and orientation.

That’s why “perfect fit” in CAD often becomes “perfectly stuck” in real life.

For injection moulding, you can design very tight tolerances,
but you pay for it in tooling cost and lead time.

3D printing is different.
It trades ultra‑tight tolerance
for speed, flexibility, and fast iteration.

The goal is not “perfect fit,”
but “good enough fit that actually works”.

If you are designing assemblies, housings, or fixtures,
and you are not sure how much clearance to add,
we can help you design a simple test block
and print it before committing to the final part.

Come talk to us to discuss your next project!

Multi‑part vs one‑part design — what we’ve learned from real parts

We get a lot of CAD files that look great on screen.
People often say:
“I can print this in one piece — so I should.”

That’s not always true.

Sometimes a single‑part design is a design trap, not a DfAM win.
Other times, splitting a part into multiple pieces is the smarter, cheaper, more reliable choice.

👉 When we print in one part
- Simple geometry, no moving parts.
- No tight internal channels.
- No need for assembly or service.
- No crazy overhangs or impossible supports.

One‑part works well when it actually saves time, cost, and risk — not just “looks clean in CAD.”

👉 When we split into multiple parts

- Any part with moving components (hinges, shafts, sliders).
- Any part with hard‑to‑reach interiors or long support channels.
- Any part that needs to be serviced or replaced.
- Any part that would need massive supports or extremely long print time.

Splitting:
- Reduces print time and material.
- Improves surface quality.
- Makes inspection and maintenance possible.
- Often improves reliability.

👉 A simple rule we use
Think about function, not unity.

If the part:
- has moving parts,
- needs to be serviced, or
- would be hard to print or clean,

it is often better as a well‑designed multi‑part assembly — even if it is “less elegant” in CAD.

Design for 3D printing is not about printing everything in one go.
It is about choosing the structure that actually works in real life — and that everyone can manufacture, inspect, and maintain.

Come talk to us to discuss your next project!