In FDM, what is the consequence of having walls that vary significantly in thickness?

In Fused Deposition Modelling (FDM), having walls that vary significantly in thickness can lead to uneven stress distribution during the printing process. When walls are of inconsistent thickness, some areas may be overbuilt while others are underbuilt. This inconsistency can cause parts to warp or fail, especially under mechanical loads or temperature changes.

As the extruded material cools, thinner sections may cool and contract more quickly than thicker sections, leading to stress concentrations. These stress concentrations can ultimately compromise the structural integrity of the print, potentially resulting in cracks, warping, or even complete failure of the part. Therefore, ensuring uniform wall thickness is crucial for maintaining the strength and reliability of the printed object.

The other options do not directly highlight the implications of varying wall thickness. While faster printing (one option) and reduced material use (another) might seem beneficial in theory, they do not address the fundamental issue of structural integrity that arises from non-uniform thickness. Additionally, varying thicknesses do not inherently contribute to better thermal conductivity, which could actually be hindered by inconsistency. The focus on stress distribution accurately captures the core consequence of differing wall thicknesses in FDM.