• Post category:3D Printing

If you’re looking to create parts that are both strong and durable, you’ll need to use 3D print interlocking parts. 3D printing is a versatile technology that can be used to create a wide range of parts, from small components to entire structures. But how do you ensure that your parts are actually strong and durable?

In this article, I will provide a complete guideline on how to create strong and durable 3D printable parts using Interlocking Joints. I will also discuss the different types of 3D printable joints and how they can be used to create parts that are both reliable and sturdy. I hope you will find this guide useful!

3d printing interlocking parts

How 3D Printing Interlocking Parts Will Benefit You?

3D printing, also known as additive manufacturing, is a process where objects are created by depositing materials layer by layer. In 3d printing interlocking parts, different 3d printed joinery are connected together so that they can be easily separated and taken apart without damaging the entire object.

  • Interlocking parts in 3D printing allow for more customization and versatility in devices and products while reducing costs and waste during production.
  • This allows for components to be customized or replaced without having to disassemble the entire device.
  • If a component breaks in an automated machine, it is easier to fix or replace it with an interlocked part than with non-interlocked parts.
  • Another benefit of interlocking parts in 3D printing is that it helps reduce costs and waste during production. If a component needs to be replaced due to wear and tear, it will not have to be replaced with a new one entirely. Instead, you can separate it from the rest of the device and replace it with a new component at a fraction of the cost or waste of replacing it completely.

Some Technologies for 3D Printing Interlocking Joints

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS) is a 3D printing technology that uses a laser to sinter or fuse layers of material together. This creates strong, durable objects with fine detail and sharp edges. SLS is most commonly used in the manufacturing industry, where parts can be customized to a high degree and quickly produced. It is also used in the design and engineering sectors, where it can create complex shapes, such as 3d printing interlocking joints, by combining multiple layers of material.

  • Selective laser sintering is a cost-effective and rapid manufacturing process for small-scale parts.
  • It has many applications in fields such as aerospace, medical devices, and consumer products. SLS boasts several advantages, including high precision and durability. These qualities make it ideal for the production of high-quality, repeatable parts in industries such as manufacturing and medicine. 
  • Selective laser sintering has been widely adopted by manufacturers across industries for its high-quality parts and short production times. The technology has helped manufacturers reduce their costs and increase their production efficiency by producing custom parts more efficiently. 

Digital Light Processing (DLP)

Digital Light Processing (DLP) is a technology used in 3D printers to produce high-quality, detailed 3D prints. It provides a faster and more precise way to make complex shapes and structures. DLP uses a series of light-emitting diodes (LEDs) to drive the movement of a liquid resin through a system. This allows the resin to harden into solid objects as it is exposed to the LEDs. In DLP, there are three main components:

1. The LED Array: This is where the LED lights are arranged and controlled. It determines the shape and intensity of the light output produced by the system.

2. The Drive Unit:  This is where the resin enters the system and where it is dripped onto a build platform. It contains pumps, valves, and other hardware needed for distributing and dispensing the resin within the system.

3. The Build Platform:  This is where 3D printing takes place, typically on a material such as acrylic or metal. It can be a benchtop or an industrial-grade large tabletop printer. There are a few key features of DLP that make it particularly suited for 3D printing:

  • High Precision: because the light is controlled so precisely, each layer can be created with incredible accuracy. This means even small details can be accurately printed without having to reprint or remove parts.
  • Speed and efficiency: Due to its automated system, DLP printers are much faster than traditional 3D printers. This means you can create larger objects in less time and with less effort.
  • Variety of Materials: Because DLP prints using a resin rather than plastic, it is suitable for printing a wide range of materials, including metals and polymers.

Fused Deposition Modeling (FDM)

Fused deposition modeling (FDM) is a 3D printing technology that allows for the production of intricate and functional parts by melting and extruding materials together in a controllable manner. FDM is an advanced form of selective laser sintering (SLS), which uses a laser to fuse small particles together to form a solid object. In contrast to SLS, FDM offers several advantages, including higher resolution, faster production times, and more control over the final product.


  • One of the main advantages of FDM is its versatility. FDM can be used to produce parts from a wide range of materials, including plastics, metals, and resins. This allows for the creation of products with a wide range of functionality and properties. The ability to customize parts using FDM makes it an attractive option for companies looking to add new functionality or improve existing products.
  • Another advantage of FDM is its flexibility and scalability. FDM can be used in both small-scale laboratories and large-scale manufacturing facilities, allowing companies to scale up their operations as needed. In addition, FDM is suitable for producing complex parts with multiple components in complex geometries. This makes it suitable for applications where precise fit and alignment are required, such as medical devices or aerospace components.

Challenges You May Face for Fused Deposition Modeling 

There are a few key challenges that companies must address when adopting FDM technology:

Quality Control: As with any 3D printing process, there is the risk of quality issues when producing parts using FDM. To mitigate this risk, manufacturers should adopt rigorous quality assurance procedures and use high-quality materials in their products. In addition, they should employ automated QC processes to ensure consistent accuracy throughout the manufacturing process.

Design Flexibility: Due to the nature of FDM printing, parts can be very customizable and idiosyncratic. This makes it difficult to produce reproducible products. To overcome this challenge, manufacturers should adopt standardized designs and rigorous quality control procedures that can minimize the likelihood of part variation.

Machining Complications: Parts printed using FDM often require more manual machining than traditional parts manufacturing processes. This is due to the intricate geometries that are common in 3D printing applications. To reduce machining costs and time, manufacturers must take into account the specific features of their FDM prints when planning setup and execution times for their production lines.

Stereolithography (SLA)

Stereolithography (SLA) is a technology used to create 3D objects by printing them in layers. It involves the use of special liquid resin and laser light to harden the resin and form the object. The process is similar to that used in traditional printing, but instead of using ink or other liquid, resin is used.

Stereolithography (SLA) for 3D Printing Interlocking Parts
  • You can use SLA  to create complex objects with intricate details, such as interlocking joints for cars or aircraft components. SLA is also useful for creating prototypes that can be tested before mass production.
  • The key advantages of SLA include its flexibility and precision. With traditional manufacturing techniques, it can take a long time and a large amount of material to produce a single part. With SLA, on the other hand, it is possible to produce multiple parts with just one model and reduce production costs.
  • Although stereolithography is an advanced technique, it can still be cost-effective compared to other methods of manufacturing. This makes it an ideal choice for small-scale or prototype manufacturing needs.
  • There are a few disadvantages of SLA. One is that it can be time-consuming and labor-intensive to use. Another is that the finished product may not always look exactly like the model used in the initial prototype.

What Are the Challenges You Should Have in Your Mind for 3D Printed Joinery?

The challenges of 3d printing interlocking parts are varied, but each one has its own unique set of challenges.

  • One such challenge is the difficulty in accurately designing and printing wood components with precise details. This can be especially challenging when working with complex shapes and intricate details, such as curves or corners.
  • Another one is the need for strong, durable material choices that can withstand the rigors of a project’s construction and long-term use. 
  • It is important to choose the right printer and materials to suit a given project’s requirements and needs.
  • This can be particularly difficult when working with curves or corners, which may require special software to correctly model and print. 
  • Material choices play a significant role in how well 3D-printed components hold up over time. Oftentimes, strong, durable materials are needed for durable projects that will be used regularly.
  • The different types of printers available also affect the types of materials that can be used with them. Suppose, layer-printing printers tend to use softer materials that may not withstand as much wear and tear. But on the other side, powder-based 3D printers use a powdered form of resin that is then melted to create the object being printed.

What Can You Do to Overcome Such Challenges?

  • It is important to have a good understanding of how 3D printing works and the various technologies available. This will help you find the best printer for a specific project and select the proper material types.
  • Using specialized software can help you correctly design your components and avoid common issues that can arise during printing. One of the most common challenges with 3D-printed joinery is accurately designing and printing complex shapes.
  • When choosing a printer, it is important to consider the specific needs of the project. Some printers are better suited for printing small objects while others are better suited for printing large objects. Different types of materials require different types of printers to produce accurate results. 


3D printing has revolutionized the way objects are created and prototypes can be quickly and cheaply created. 3D printing interlocking parts technology has also made it possible to create complex and intricate 3D parts that are difficult or impossible to manufacture using traditional manufacturing methods. In this blog post, we will provide a guideline on how to design and print interlocking 3D parts that are easy to assemble and maintain. By following this guideline, you can ensure that your 3D parts are both reliable and durable.