HOLDS. Peak 11 MPa on face 19 at (24.7, 6.09, 1.96), safety factor 4.27 against yield (target 2.5). Confidence is medium.

Confidence: medium. mesh convergence: von Mises stress (layer pull scaled by layer strength) still moving: 9.91 -> 11.1 -> 10.3 -> 11 MPa, last change 6.6% (stopped by level limit); expect about that much error. Even the highest value on any mesh plus that swing (11.8 MPa) leaves safety factor 3.99, so the verdict holds either way; singularities: excluded from the answer: 53.9 MPa at the edge of support fix1 (face 1) (set by the idealized support: 36 -> 47.7 -> 46.3 -> 53.9 MPa); 26.9 MPa at the edge of support fix1 (face 1) (set by the idealized support: 33.4 -> 23.5 -> 32.6 -> 26.9 MPa); 20.1 MPa where the rigid attachment load1 grabs the part (face 9) (set by the idealized support: 21.1 -> 15.5 -> 20.6 -> 20.1 MPa). Wobbl reports the stress 1.76 mm or more away from these spots; load introduction: the off part loads enter through a rigid attachment (the attached part does not flex). With a distributing coupling (the attached part adds no stiffness) instead, the governing stress converges to 18.8 MPa on face 5 at (21, 6.94, 37.3) (1.7x, safety factor 2.50) over 3 meshes refined around that peak: 19.2 -> 19.2 -> 18.8 MPa, last change 2.1%. The verdict depends on this assumption: check how the attached part really carries the load; the verdict depends on how the load enters the part (rigid attachment versus distributed); the answer assumes rigid
Max deflection 0.399 mm at (-25, 0, 55).
Material PETG (3D printed), limit 47 MPa; mass 39.36 g.
Loads: 250 N down at 0,-15,31 @ normal +y and box -21,4,10,21,6,52 rigid. Fixtures: bolt holes d=5.5.

Checks:
  [warn] mesh convergence: von Mises stress (layer pull scaled by layer strength) still moving: 9.91 -> 11.1 -> 10.3 -> 11 MPa, last change 6.6% (stopped by level limit); expect about that much error. Even the highest value on any mesh plus that swing (11.8 MPa) leaves safety factor 3.99, so the verdict holds either way
  [pass] force balance: reactions balance the loads to 3.4e-05% (forces) and 1.3e-05% (moments)
  [skip] hand calculation: no simple beam model applies (the governing point is not between the fixtures and the load, so no single section carries it)
  [warn] singularities: excluded from the answer: 53.9 MPa at the edge of support fix1 (face 1) (set by the idealized support: 36 -> 47.7 -> 46.3 -> 53.9 MPa); 26.9 MPa at the edge of support fix1 (face 1) (set by the idealized support: 33.4 -> 23.5 -> 32.6 -> 26.9 MPa); 20.1 MPa where the rigid attachment load1 grabs the part (face 9) (set by the idealized support: 21.1 -> 15.5 -> 20.6 -> 20.1 MPa). Wobbl reports the stress 1.76 mm or more away from these spots
  [pass] bolt bearing: worst hole of fix1 (d 5.5 mm) carries 68 N sideways and 147 N along its axis; bearing stress 2.46 MPa, safety factor 19.11 on bearing
  [pass] units and sanity: part 102 mm across, peak strain 0.0052, max deflection 0.399 mm (0.39% of size): all plausible
  [warn] load introduction: the off part loads enter through a rigid attachment (the attached part does not flex). With a distributing coupling (the attached part adds no stiffness) instead, the governing stress converges to 18.8 MPa on face 5 at (21, 6.94, 37.3) (1.7x, safety factor 2.50) over 3 meshes refined around that peak: 19.2 -> 19.2 -> 18.8 MPa, last change 2.1%. The verdict depends on this assumption: check how the attached part really carries the load

Assumptions:
  - Linear elastic material and small deflections (no yielding redistribution, no buckling).
  - PETG (3D printed): E 2100 MPa, Poisson 0.38, von Mises vs yield 47 MPa (Prusament PETG technical data sheet).
  - Loads are static and applied all at once; no impact, vibration or fatigue.
  - Printed layers stack along z; pull across layers is judged against 70% of the in-plane strength.
  - Bolted holes are rigidly held over the hole and a washer sized ring (twice the hole radius).
  - Remote loads reach the part through a rigid attachment (the attached part does not flex).
  - Contact between separate parts, friction and preload are not modeled.

Images: stress: images/stress.png, zoom: images/zoom.png, safety: images/safety.png, deformed: images/deformed.png, convergence: images/convergence.png
Report: report.html
