Proposal for a Modeling Technique to Install Tapping Screw Bosses at the Four Corners of a Box

Generally, bosses for tapping screws installed on the top surface take an overhang shape. Traditionally, to alleviate the overhang, it was necessary to install supports or model the bottom of the boss with a tapered shape. However, these methods required an increase in printing time and cumbersome modeling.

In this study, we propose a new method that minimizes both modeling effort and printing time.

Specifically, we draw a triangle on the bottom surface of the boss as shown in the attached figure. This triangle is printed as a bridge of straight lines, starting and ending at the respective orthogonal outer walls.

The triangle thus installed serves as a foundation for printing the boss. Since the triangle is printed in only one layer, it significantly reduces printing time compared to other methods. Moreover, it is easier to model than a tapered shape.

The attached model is intended for analysis in a slicer.

Note: When using tapping screws, it is important to choose a flexible material like PETG or ABS. Some types of PLA have low flexibility and may break when using tapping screws. However, in my experience, Prusament's PLA did not pose any problem.