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Breaking the Chain: Pushing GrabCAD Print Pro to its Limits

Adrian Ilie, Sr. QA Engineer, GrabCAD, Stratasys

Adrian Ilie

Sr. Manager, QA Engineering | Stratasys/GrabCAD Software

4월 24, 2025

GrabCAD design of chain links using Stratasys SAF Material
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As a QA Engineer at Stratasys' Cambridge office, I'm used to testing the boundaries of our software. Recently, I stumbled into a challenge that put GrabCAD Print Pro through its paces in an unconventional way.

The Catalyst: A LinkedIn Post

While scrolling LinkedIn, I came across a post that caught my eye: a colleague had created an 83-meter chain with 2,519 links, all in one build, using Magics software. As someone who spends their days probing the limits of our systems, I immediately wondered: Could I surpass this length using our own GrabCAD Print Pro software?

Challenge Accepted: Exceeding 83 Meters

Without hesitation, I set out to create a longer chain using GrabCAD Print Pro's 3D Array tool. This feature, typically employed for part replication and stacking, would be the cornerstone of my attempt. My goal was straightforward yet ambitious: exceed 83 meters and showcase the capabilities of our software in the process.

The Technical Rundown 

  1. I designed a single chain link, optimized for printability and interlocking capability.
  2. Using the 3D Array tool, I replicated the link vertically. The challenge here was maintaining precise inter-link spacing.
  3. I relied heavily on the software's preview function, which was crucial for ensuring the build remained within the printer's parameters.
  4. To prevent link fusion, I used the Section View tool extensively. This allowed for micron-level spacing inspection.
  5. Through iterative adjustments, I incrementally optimized the build volume utilization.
A chain 3D printed using SAF material on GrabCAD software

Results: Breaking the Chain Barrier

After numerous iterations and meticulous optimization, the final build plan emerged: a chain approximately 87 meters long, comprising 2,645 individual links. This not only surpassed the original benchmark but also demonstrated the robust capabilities of GrabCAD Print Pro.

Stratasys GrabCAD Screengrab of a SAF Chain

Key Technical Insights

  • The 3D Array feature proved more versatile than initially anticipated, particularly for arranging parts on the Z axis. This capability allows for efficient stacking of parts, significantly reducing build times and increasing throughput.
  • Section view emerged as a critical tool for quality assurance in complex, high-density builds.
  • The entire exercise revealed potential areas for software enhancement, particularly in automated spacing optimization for intricate, repeating structures.

Take-away

While my experiment focused on SAF technology, the principles apply across various 3D printing methods, including FDM. I encourage fellow engineers to explore the full potential of GrabCAD Print Pro with your own experiments. By leveraging tools like 3D Array and Section View, you might uncover capabilities you hadn't considered before.

Try It Yourself

For those of you eager to experiment with this concept, Stratasys is making the CAD chain design available in both GrabCAD and Magics formats. Download the files and test the limits of your own setup, whether you're using SAF technology, FDM or another 3D printing method. It’s a great opportunity to investigate every facet of your software and hardware while pushing the boundaries of what's possible in additive manufacturing.

If you have technical questions about this process or want to discuss potential GrabCAD Print Pro applications, feel free to reach out.

For a comprehensive guide on using the 3D Array feature, check out our full tutorial on YouTube: GrabCAD Print Pro Tutorial: How to Stack Parts with 3D Array

This video walks you through the process step-by-step, helping you maximize your build efficiency and throughput.

Featuring GrabCAD Print, an Additive Manufacturing (3D Printing) Software.

Try It Yourself