Why are sharp angles generally discouraged in FDM part designs?

Sharp angles in Fused Deposition Modelling (FDM) part designs are discouraged primarily because they can weaken the structure and lead to failure. This occurs due to the nature of the 3D printing process itself, where materials are deposited layer by layer. Sharp transitions can create stress concentrators within the material. These areas are more susceptible to cracks or fractures when the part is subjected to stress or load.

Additionally, during the printing process, the sharp angles can create issues with adhesion between layers. If the angle is too acute, the printer may have difficulty building the material effectively, leading to poor bonding at those points. This compromises the overall integrity of the part, making it more likely to fail in real-world applications.

While it is true that sharp angles may complicate the printing setup or affect the aesthetics of a part, the primary concern remains with the structural integrity and durability of the finished model. For these reasons, it’s generally advised to incorporate rounded or filleted edges in designs to enhance strength and reliability.