1-Piece Dart Flights (Fully Parametric + Fusion)

NOTES: 
1. Use TPU or it will break.
2. Challenging print. Dry filament thoroughly. Purge previous filament thoroughly (any contaminant will cause layer adhesion issues on the flights as they are very thin).

 

These 1-piece dart flights feature an integrated stem and are designed for simplicity and full customization.

Print Optimization

Each flight is modeled to print at an angle matching the rear of the dart, which increases layer contact surface and improves durability compared to darts that print vertically. 

 

Stronger than if printed vertically:

 

This angled print also eliminates the need for supports. Win win.

 

The mass of the flights with 0.4mm nozzle is around 2.1 g when printed in Nylon PA12. This is a No. 6 tweenie (intermediate) length.

 

Print Profiles

Both profiles include No 6 and No 2 flight types, each with short, tweenie, and medium stem options.

• 0.4 mm nozzle – Easier to print and more reliable, with a slightly heavier flight (minimum 0.4 mm wall).
• 0.2 mm nozzle – More lightweight and precise, but challenging to print to say the least. Bambu doesn't offer or even allow PA or TPU filament profiles to work with 0.2mm nozzles. You can make your own fake PLA profile with PA/TPU temps and calibration, or use OrcaSlicer. Less than ideal.

Parametric Customization

The provided Fusion model is fully parametric and also works with MakerWorld’s CUSTOMIZE feature. 

 

Adjust nearly every dimension:

• Stem length & diameter
• Flight width & length
• Leading and trailing edge angles & radiuses
• And more… there's a lot.

Name	Value	Unit	Comments
Shaft_Base_Diameter	5.80	mm	5.8 mm typical.
Shaft_Length	20.00	mm	Medium=32. Tweenie=26. Short=20.
Flight_Length	44.50	mm	No2=44.5. No6=42.
Shaft_Tail_Diameter	0.50	mm
Flight_Tail_Angle	65.0	deg	No2=58. No6=73… 58 can be hard to print - use 65+.
Flight_LeadingEdge_Angle	45.0	deg	No2=45. No6=44.
Flight_LeadingEdge_Radius	4.00	mm	Dart front radius. No2=4. No6=2.
Flight_Tail_Radius	10.00	mm	Rear dart radius. No2=10. No6=8.
Flight_Blade_Thickness	0.42	mm	Set based on nozzle size. 0.22 for 0.2 mm nozzle. 0.42 for 0.4 mm nozzle.
Flight_Width	36.50	mm	No2=36.5. No6=32.8.
Flight_Secondary_Angle	0.0	deg	No2=0. No6=4.

Material Recommendations

• Best: Bambu TPU for AMS, more tough than PLA Tough+ and Nylon, more rigid than regular TPU.
• Alt: TPU 95A, more tough than basically anything, but a bit floppy.
• Alt: Bambu PLA Tough+, easier to print and still decently flexible, though less durable than nylon or TPU.
• Alt: PA12 Nylon (non-carbon-fiber), harder to print, tougher than PLA Tough+, less flexible than TPU.
• Regular PLA, PETG, ABS, ASA, PC, ETC are not ideal . This design is more durable than others, but these traditional rigid filaments will break quickly.

 

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