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3D Printing Guide

Solutions for 3D Printed Springs

Picture of Scott Gabdullin
Scott Gabdullin

Updated on January 31, 2025

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If you’ve ever tried 3D printing springs, you already know they’re a little tricky. We’ve spent plenty of time experimenting with 3D printing springs. They need to be durable, elastic, and functional while dealing with the limitations of 3D printing materials and methods. It’s not uncommon to face issues like brittleness, deformation, or even outright failure when crafting these flexible components.

Let’s look at some of the solutions to the most common challenges you might face when printing springs.

Solution #1: Choose the Right Flexible Materials to Prevent Brittle Springs

One of the first issues we encountered when 3D printing springs was brittleness. It’s disappointing when you expect a spring to flex as intended, but instead, it snaps with minimal pressure. This is especially frustrating since the very purpose of a spring is to endure bending and stretching.

But why do printed springs become brittle? It often boils down to material choice or the way the spring is printed. Some materials aren’t up to the task. PLA, for instance, is popular in 3D printing due to its ease of use, but it lacks the flexibility required for functional springs.

Additionally, the printing orientation plays a significant role. Printing with layers stacked vertically creates weak points where stress can cause the spring to break easily. These weak spots are problematic in designs requiring frequent bending and movement.

So, how do we fix it? One of the first solutions for spring 3D print is choosing the right material. From experience, TPU (thermoplastic polyurethane) or other flexible filaments like TPE (thermoplastic elastomer) are a fantastic option for springs. It’s flexible, durable, and can handle repetitive stress without breaking.

For applications requiring moderate flexibility and toughness, PETG is a solid option, combining strength with excellent durability. PLA, while stiff and brittle, works well for decorative or low-stress springs and prototyping, whereas ABS is better suited for springs exposed to mechanical or thermal stress, like those in robotics or appliance parts. For the highest levels of toughness and resilience, nylon is often the material of choice, making it ideal for springs in sports equipment and medical devices.

Solution #2: Optimize Printing Orientation and Infill Density

Once you’ve selected the material, focus on the printing orientation. We recommend printing the spring along its axis rather than layering it vertically. This alignment minimizes weak points between layers, allowing the spring to handle stress along its intended direction. Proper orientation significantly enhances the spring’s durability.

Next, adjust the infill density. Springs need a balance between strength and flexibility. We’ve found that a 40–50% infill density works best, providing enough internal support for bending without making the spring too stiff. Avoid higher infill percentages, as they can reduce elasticity and compromise performance. These adjustments in orientation and infill ensure your springs are both functional and resilient.

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Solution #3: Refine Heat and Cooling Settings to Eliminate Deformation

Another common issue faced with 3D-printed springs is deformation. Sometimes a spring comes off the print bed warped or doesn’t retain its intended shape. Not only does this render the spring unusable, but it’s also an indicator that something in your printing process needs adjustment.

This is typically caused by heat-related issues, improper cooling, or poor bed adhesion during printing. When the pinger’s heat settings are off, materials can warp as they cool unevenly, resulting in a misshapen spring. Cooling problems can exacerbate this by causing the material to contract too quickly or inconsistently. In some cases, the design itself may be the root of the problem, especially if the coils are too thin or not optimized enough for 3D printing.

As one of the solutions for spring 3D printing, one effective approach is to start by reviewing your spring design. A poorly designed spring will be more prone to deformation, no matter how well you dial in your printer’s settings. Using a CAD program, carefully adjust the dimensions to ensure the coils are thick enough to resist stress but not so rigid that they lose elasticity. A good design sets the foundation for a functional spring.

Next, take a close look at your heat settings. Printing with materials like TPU requires precise temperature control. Keeping the extruder temperature between 220-250°C and using a heated bed set to 40–60°C consistently yields good results. These settings make sure that the material flows properly and adheres to the bed without overheating, which can lead to warping.

Cooling is another critical factor. Moderate cooling works best for materials like TPU and TPE. Set the fan speed to 50-60% to prevent overheating while allowing the material to cool evenly. This balance is key to maintaining the spring’s shape and avoiding issues like sagging or uneven layers.

Solution #4: Add Supports to Stabilize Complex Spring Designs

When printing springs with overhangs or intricate geometries, supports are a must-have. These structures play a crucial role in stabilizing the print and ensuring that every part of the spring retains its intended shape during the process. Without supports, overhangs might sag, layers could collapse, and the spring’s functionality would be compromised.

We always start by identifying areas of the design that are prone to instability. Overhangs, steep angles, or unsupported coils are key spots that benefit from additional support. By enabling support structures in our slicer software, we create a temporary framework that holds these sections steady while the printer does its work. For springs with intricate designs, we often use tree-style supports, as they offer excellent stability with minimal material usage and are easier to remove.

However, adding supports is only half the battle. It’s equally important to remove them carefully. Flexible materials like TPU can be delicate, and excessive force during removal can damage the spring. To avoid this, we recommend using tools like pliers or precision cutters to gently separate the support material without harming the print. For particularly complex designs, we sometimes adjust the support density in the slicer, striking a balance between stability and ease of removal.

Solution #5: Adjust Design and Printing Parameters for Better Spring Performance

Sometimes, a spring prints flawlessly. It looks great, feels sturdy, and has no visible defects. But when you test it, it doesn’t behave as expected. It might be too stiff, over-flexible, or simply not elastic enough to function properly.

A spring’s performance is influenced by several key variables: the design, the material used, and the printing parameters. Even minor adjustments in any of these areas can lead to significant differences in how the spring behaves.

In improving the performance, one of the first things we look at is the thickness of the spring’s coils. Ticker coils tend to make the spring stiffer, which is great for applications requiring strength and minimal movement. On the other hand, thinner coils increase flexibility, making them more elastic and capable of handling larger deformations. Depending on the intended use of the spring, tweak the coil thickness in a design software to meet specific needs.

Next, we take a look at layer height as this is another significant factor. We’ve consistently achieved better performance by using a smaller layer height, typically in the range of 0.1–0.2 mm. A smaller layer height improves the precision of the print, ensuring that each coil is as smooth and accurate as possible. This precision reduces imperfections that could compromise the spring’s functionality.

Lastly, experiment with the overall dimensions of the spring. Longer springs tend to be more flexible, as they distribute force across a greater distance. Conversely, shorter and wider springs are stiffer and better suited for applications requiring higher resistance. By testing variations in length, diameter, and coil spacing, you can refine the spring’s performance to match the specific demands of the project.

Solution #6: Optimize Nozzle Temperature and Print Speed for Stronger Layer Adhesion

One of the more frequent issues we’ve experienced when 3D printing springs is poor layer adhesion. Cracks or delamination between layers can undermine the spring’s structural integrity, ultimately rendering it unusable. That’s a big setback when you’re counting on a spring to handle repetitive stress without failing.

In our projects, we’ve noticed that low extrusion temperature or printing at too high a speed can be major causes of weak layer bonding. If the temperature isn’t high enough, the filament won’t fuse solidly with the layer below. Printing too quickly can also be a problem because the filament doesn’t have enough time to form a reliable bond before the printer head moves on.

We address these concerns by making an initial adjustment: increasing the nozzle temperature. When printing with flexible materials, we’ve had the most success at the higher end of its recommended range, around 240–250°C. This ensures the filament melts completely and adheres firmly to the previous layer, creating a stronger bond.

If you’re experiencing weak adhesion, we suggest gradually increasing the temperature while keeping an eye on the print quality to find the sweet spot.

The next solution is to reduce the print speed. Slowing down to 20-30 mm/s will achieve better adhesion, especially for intricate or high-stress components like springs. A slower speed allows the filament to properly fuse with the layer below, reducing the risk of delamination or cracking. It may add some time to print, but the improved quality is well worth it.

Solution #7: Inspect and Maintain the Nozzle for Consistent Results

Keeping the nozzle in top condition is one of the most critical steps for ensuring consistent and high-quality spring 3D print. A clogged or worn-out nozzle doesn’t just lead to inconsistent extrusion, but it also affects layer bonding, creating weak spots that can compromise the durability of your spring.

Start by routinely inspecting the nozzle for signs of clogs or wear. Even minor blockages can disrupt filament flow, leading to under-extrusion, rough surfaces, or uneven layers. Using tools like a nozzle cleaning kit or small needles, clear out any debris or leftover filament buildup. It’s a quick process that helps keep the filament flowing smoothly.

For more persistent clogs or when printing with materials prone to residue, like these two materials: TPU or PETG, occasionally remove the nozzle and perform a deeper clean. Heating the nozzle to soften any stuck material and using a brass wire brush to remove residue ensures it’s thoroughly cleared.

When wear becomes evident, such as changes in extrusion quality despite cleaning, it’s time to replace the nozzle. Nozzles can wear out over time, especially when printing abrasive materials like carbon fiber-filled filaments. Swapping in a new nozzle restores precision and extrusion reliability.

Solution #8: Use Rounded Edges to Minimize Stress Concentrations in Springs

We’ve noticed that sharp corners in spring designs often become stress concentrators, which weakens the spring and can lead to failure when it’s placed under load. This is especially true for spiral or flat springs, where even minor imperfections can create significant imbalances in stress distribution.

Whenever there’s a sudden shift in geometry, like a sharp corner, force tends to build up in that area. Over time, repeated bending or compression will exploit those weak spots, eventually causing cracks or breaks.

The most effective way we’ve found to address this issue is by incorporating chamfers or fillets into the design. Fillets are rounded edges, while chamfers are angled ones, and both help distribute force more evenly across the spring. These features can significantly reduce stress concentrations, improving the spring’s resilience. If you’re using modeling tools like Fusion 360 or SolidWorks, applying fillets or chamfers is straightforward. We often use these tools to refine the intersections between coils or at points where the spring attaches to other components.

Solution #9: Optimize Transitions to Eliminate Weak Points

When designing springs, one of the most critical things you should focus on is avoiding weak points caused by abrupt transitions. Sudden changes in thickness or sharp geometry can create stress concentrations, making the spring prone to failure under even moderate loads. These weak areas are like cracks waiting to happen, and we’ve seen firsthand how they can compromise the performance and lifespan of a spring.

To address this, we put extra care into designing gradual transitions. For example, instead of having a sudden change in thickness, we taper it smoothly, allowing the forces to flow naturally through the spring. Similarly, we round the edges in areas where sharp corners might otherwise act as stress magnets. These small tweaks may seem minor, but they make a huge difference in how the spring handles stress and recovers after being compressed or stretched.

We’ve noticed that springs with smoother transitions not only perform better but also have a significantly longer lifespan. This technique has become a cornerstone of our design process, and it’s something we always double-check before moving forward with printing.

Solution #10: Keep Filament Dry and Dust-Free for Superior Surface Quality

When it comes to improving the surface quality of our 3D-printed springs, one of the most critical factors is the condition of the filament itself. Moisture is a common enemy of good 3D printing results. If filament absorbs even small amounts of moisture from the air, the water turns into steam during extrusion, causing bubbles, tiny pits, or inconsistent layer adhesion on the print surface. 

We suggest storing all filaments in airtight containers with desiccant packs to absorb any residual moisture. For materials like TPU and nylon, which are particularly hygroscopic, we sometimes use a filament dryer before printing to ensure the filament is completely dry. This extra step has consistently resulted in cleaner, more reliable prints, especially for intricate designs like springs.

Dust and debris can also be a major problem, as they can clog the nozzle or cause uneven extrusion, leaving visible imperfections on the surface. Inspect your filament before every print and run it through a filament cleaner or filter if needed. Our aim is to minimize extrusion issues and achieve springs with a clean and professional finish. 

Perfect Your Process for Reliable Spring Printing

Successfully 3D printing springs requires a combination of careful planning, precise settings, and smart design adjustments. From addressing brittle failures to ensuring strong layer adhesion and reducing stress concentrations, each step plays a critical role in achieving functional, durable springs. By applying the solutions we’ve covered, you’ll not only overcome common challenges but also unlock the full potential of your 3D printer for intricate and demanding designs.

For more practical insights, step-by-step guides, and expert recommendations, make sure to explore 3DGearZone. Whether you’re fine-tuning your spring designs or tackling other complex prints, we’re here to help you transform your ideas into reality.

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