This is the first 3D print layout. The three nuts are different sizes becuase 3D printing is a collection of linear movements so the surface
is not curved. Different sizes have to be tried to get the best fit. The female threaded nuts are changed to find the best fit with the least
amount of waste.
The resolution is Z 0.004" and X,Y 0.015".
The male will come through to the end of the nut thread shown above. The goal is for the male thread to be even with the surface of the female thread.
Not inside or outside, but even as shown in the above drawing.
3D printing is a collection of linear movements, so the surface is not curved. Different sizes have to be tried to get the closest surface contact. There are 5 female nut threads Nut A:+0.005"; Nut B:+0.010"; Nut C:+0.015"; Nut D:+0.020"; and Nut E:+0.025". The middle nuts B, C and D are suggested. Experience has shown the 0.015" of Nut C will be the most common one to work, but different machines and different resolutions .
It is better to test the threads with smaller files. Each of these are different heights shown so they can be kept seperate. Print the bolt first, then print the B and C test thread and see if the come out even as shown above.
pick the sizes and down load by double clicking on them. Then test them with the bolt below
These are the full size wave thread Nuts. After the above testing, pick the letter size that fit the best.
Wave threaded Bolt with a 1" shank. Bolt_AZ2KB_S1.STL
Next are the corresponding UNC (Unified National Course) threaded nut and bolt. The larger nut is for use in destructive testing.
This has a 7/8" diameter with 9 TPI (Threads Per Inch).
The bolt has a 1" shank and 2" thread designed for destructive testing in comparison with wave thread.
The 0.75" nut is the standard size for this bolt. The 1.5" nut to match the length of the wave threaded
nut for destructive testing. Both wave and UNC bolts have the same clamp length, the 1" shank.
These nuts and bolt are class 2, the most common. Classes are a measure of fit and class 2 is larger enough for 3d printing. 3D printing is a collection of straight lines which effects how well threads fit. The wave threads are total surface contact so the fit has to match the printer resolution as close as possible.
The 7/8 UNC stud is similar to the bolt execept with thread on each end. The second stud with a UNC and Wave thread on each end is for destructive testing. The third is Wave thread on each end. One destructive test of 3D printed parts pulled the heads of the bolts off while the Wave threades studs were 17.5% stronger then they were supposed to be. The studs are specifically for destructive testing to produce a strength of UNC threads only, NUC and wave threads; and wave threads only. It is expected that the wave thread only parts will have the strongest tensile strength.