Multi-Tolerance Test Card

Introduction

If you are creating models for 3D printing, with either fixed or moving joints, you'll recognize the importance of getting your tolerances right.

This compact, credit card-sized Multi-Tolerance Test Card, is designed to help you identify the ideal tolerances for your designs before having to print them, saving you a lot of unnecessary thinking and failed prototypes.

Print it now and increase your confidence in your 3D design process! ☺️

Model highlights

Up to 54 + 12 tolerance tests.
Compact credit card size.
Dedicated slots for saving testing poles.
Fully 3D printed, single color, no supports.

Three versions, under one Print Profile

Card with title on the side: Nzz 0.4 - Lh 0.2
Card with title on the side: Nzz 0.2 - Lh 0.1
Card without title on the side.

Where Nzz = Nozzle, and Lh = Layer height.

⚠️ Please notice: There is no difference in tolerances or print settings between these three versions, the only difference is the title on the card. This is indented for those who want to have the print settings (I included only the most common) written in the card, as that can have an effect on tolerances.

Tolerances

This card will allow you to test a number of tolerances of different types:

54 Assembly tolerances:
- Horizontal hole (0 degrees) x 3 poles (0, 45, 90 degrees) x 6 values.
- Vertical hole (90 degrees) x 3 poles (0, 45, 90 degrees) x 6 values.
- Inclined hole (45 degrees) x 3 poles (0, 45, 90 degrees) x 6 values.
12 Print-in-place tolerances:
- Horizontal shaft or wheel x 6 values.
- Vertical shaft pr wheels x 6 values.

All poles and shafts are 5 mm in diameter, while holes range from 5.1 to 5.6 mm in diameter.

⚠️ Please notice:

Some of the print-in-place wheels may come out fixed, stuck, merged with the card. This is not a bug, but a feature. It's telling you where the tolerance threshold is for print-in-place joints.
Tolerance values specified in the card refer to the theoretical gap between the pole and the hole, not the total clearance. In other words, it's the difference between the pole and hole radii, not diameters. See table below for clarification:

Pole Diam.	Hole Diam.	Difference	Gap / Tolerance	Units
5	5.1	0.1	0.05	mm
5	5.2	0.2	0.10	mm
5	5.3	0.3	0.15	mm
5	5.4	0.4	0.20	mm
5	5.5	0.5	0.25	mm
5	5.6	0.6	0.30	mm

How it works

To test assembly tolerances, pick one set of holes (0, 45 or 90 degrees) and one pole (0, 45 or 90 degrees), according to the assembly orientation you want to test. Then, try to insert the pole into the different holes, ranging from 0.05 to 0.30 mm of tolerance, and try to feel which one will work best for your application.

To test print-in-place tolerances, simply pick an orientation (0 degrees or 90 degrees). Then, try to move the different wheels with your fingertips, ranging from 0.05 to 0.30 mm of tolerance, and try to feel which one will work best for your application.