I was testing a new topology optimization software, and having issues with a real life part, decided to try the simplest thing I could think of: A shelf mount. This part is optimized for maximum load with minimal material use. The screenshot shows the part under a 50 kg (110 lbs) load (!), with material stress staying under 20 MPa.
In addition, the part is designed to print completely without supports. Print time around 5 hours on my Prusa i3 MK3s.
Printer Brand: Prusa
Printer: I3 MK3S
Rafts: No
Supports: No
Resolution: 0.2mm
Infill: 100%
Filament: Doesn't matter ABS or PETG
Notes:
It will probably also be fine with 30% infill, however in that case the permanent compression under the screw head might cause long term problems. 100% infill doesn't add a lot of material, since most of the part is already very thin. Print with at least 2 shells, 3 is better.
CAD work with SolidWorks 2017, topology optimization with ANSYS Discovery Live Beta.
The author marked this model as their own original creation. Imported from Thingiverse.