What is the purpose of implementing fillets in Fused Deposition Modeling (FDM)?

Implementing fillets in Fused Deposition Modeling serves a vital role in reinforcing features to improve structural integrity. Fillets are rounded transitions between two surfaces or edges in a design. By creating these smooth curves rather than sharp angles, fillets help to distribute stresses more evenly across the part, which minimizes stress concentrations that could lead to failure. This is particularly important in 3D-printed parts, as they can be more susceptible to mechanical failure at sharp corners due to weak points in the material.

In contrast, making edges sharper can increase the likelihood of stress points that can compromise the durability of the print. While reducing material usage and decreasing printing time might seem advantageous, these factors are secondary to the primary goal of enhancing the overall strength and usability of the printed component. Using fillets fosters a design that is not only functional but also better suited for its intended load and operating conditions.