Can you really 3D print working springs?

Yes! TPU and Nylon produce functional springs with good fatigue life. PETG works for light-duty springs. PLA is too brittle for repeated compression. Design with thicker wire cross-sections than metal springs to compensate for lower material strength.

What material is best for printed springs?

TPU 95A is the best for springs that need large deflection (like bumpers and dampers). Nylon is excellent for moderate springs with good fatigue life. PETG works for light-duty applications. Avoid PLA as it will crack under repeated stress.

How do I prevent spring failure?

Keep the maximum strain well below the material limit. Use generous fillet radii at all transitions. Print with the spring axis vertical for best inter-coil consistency. Avoid sharp corners which create stress concentrations.

What wire cross-section should I use?

For FDM printing, use rectangular wire cross-sections of at least 1.5mm x 1.5mm. Square or rectangular cross-sections print better than circular ones on FDM printers. Wider wire = stiffer spring.

3DPrintCalcs

Spring Calculator — 3D Printed Spring Dimensions

Calculate dimensions for 3D printed helical springs and leaf springs.

Spring Type

Material

Outer Diameter

Number of Coils

Wire Width

Wire Height

Coil Pitch

How We Calculate This

Spring Calculations

Helical spring rate = (G x b x h³) / (5.6 x n x D³)
Leaf spring rate = (4 x E x b x h³) / L³
Max deflection = Free length x Max strain x 2
Max force = Spring rate x Max deflection

Where G = shear modulus, b = wire width, h = wire height, n = coils, D = mean diameter, L = span length. 3D printed springs use rectangular wire for better printability.

Frequently Asked Questions

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Last updated: February 2026

All calculations are estimates. Always verify settings with test prints before committing to final prints.