Why Do Heat Set Inserts Fail When the Hole Is Too Small?
Heat set inserts fail when the hole is too small because the insert forces too much plastic outward, creating radial stress, boss cracking, deformation, poor alignment, or layer separation.
Boss Deformation
What Causes Boss Deformation Around Heat Set Inserts?
Boss deformation around heat set inserts happens when the printed boss cannot maintain shape under installation heat, radial pressure, screw preload, material creep, or repeated assembly.