INSTRUCTIONS
Print Guide
Build a complete shaft-and-flight system, inspect the merged model and test how your printer, material and barrel work together.
CONNECTION AND SEATING FACE
Measure the barrel diameter where the shaft sits and enter it as Shaft Ø at barrel. Select external 2BA for the common female dart-barrel connection. Select internal M3 × 0.5 only when the matching part has a male M3 thread. Measure the useful thread height or depth and start with Normal fit. Loose and Tight compensate for small printer and mating-part tolerances.
LENGTH, END DIAMETER AND PROFILE
Set the shaft length and flight-side diameter. The complete system length is the shaft length plus Flight overhang. Choose Linear or Conical Curve and use curve factor and position to shape where the shaft becomes narrower. Optionally add a transverse Ø 2 mm tightening hole just above the thread.
PRESET, POINTS AND CORNER RADII
Begin with the default Standard No2 profile or choose Standard No6, Kite, Pear or Slim. You can also edit any preset into a custom profile. Drag points in the millimetre grid, bring them down to Y = 0 when needed and use the inspector for exact coordinates and corner radii.
ONE MERGED PRINTABLE MODEL
Review the complete preview in Step 03. The flight occupies the final section of the shaft instead of being placed on top of it. Rotate and zoom the model and check the transition, wing shape and overall proportions before downloading.
TPU, 0.4 MM NOZZLE, 45° DEFAULT
TPU is the preferred experimental starting material for a flexible flight system. With a 0.4 mm nozzle, start at 0.16 mm layer height and use 5 wall lines. Use a low print speed: reducing vibrations in the long shaft and thin flight surfaces can noticeably improve the result. The STL rotation defaults to 45° and can be adjusted from 0° to 90°. Enable supports with a 20° threshold angle only around the flight. Inspect the support placement in the slicer and keep the rest of the shaft and the thread free of support.
ONE PROTOTYPE BEFORE A FULL SET
Let the print cool, separate the raft and remove supports carefully. Trim strings and lightly finish rough edges with fine sandpaper for a cleaner surface. Screw the shaft in only hand-tight and stop when its seating face meets the barrel. Excessive torque can strip or break the fine printed 2BA or M3 thread. This risk is especially high with rigid, brittle PLA. Before fitting a printed shaft, have a suitable broken-thread or shaft-removal tool available in case part of the thread remains inside the barrel. Inspect layer bonding and wing flexibility, then adjust the model or slicer before printing another version.
Frequently Asked Questions
01Is this intended for everyday use?
Treat the project primarily as a prototype platform for testing shapes, dimensions, materials and printer settings. A successful print may work for repeated trials, but the generator cannot guarantee service life, impact resistance or suitability for everyday or competitive play.
02Which material should I use?
TPU is the preferred starting point because its flexibility suits thin flight wings and can make the system less brittle than rigid materials. TPU hardness and behaviour vary considerably. Dry the filament, follow its manufacturer settings and print one test before committing to a full set.
03Can I print it with a 0.4 mm nozzle?
Yes. The recommended starting profile uses a 0.4 mm nozzle with a 0.16 mm layer height and 5 wall lines. The small 2BA or M3 thread and thin wings still require calibrated flow and a careful slicer inspection before printing.
04Which print orientation does the STL use?
The export is prepared with the flight side downward and the wings rotated 45° around the shaft axis. The STL rotation slider controls the complete system's tilt from 0° to 90° and defaults to 45°. Its lowest point is placed at Z = 0. This is a starting orientation: verify supports, contact points and build-volume placement in your slicer before printing.
05What basic slicer settings are useful?
As a starting point for a 0.4 mm nozzle, use a 0.16 mm layer height, 5 wall lines and supports with a 20° threshold angle. Print slowly to reduce vibrations in the tall, angled model; this can noticeably improve the shaft surface, thin wings and small details. Paint or restrict support to the area around the flight, inspect its placement carefully and leave the rest of the shaft and the small thread unsupported. Fine-tune speed, flow, retraction and support distance for your printer and TPU.
06Which thread connection should I use?
2BA creates the common external dart-shaft thread. M3 instead creates a blind M3 × 0.5 internal thread and requires a matching male M3 part; the two standards are not interchangeable. For external 2BA, Loose makes the thread smaller and Tight larger. For internal M3, Loose makes the opening larger and Tight smaller. Normal uses the nominal modeled size. These options compensate for small printing tolerances only. Never force or overtighten a printed connection, and always print a fit test first.
07Why does the thread not fit immediately?
First confirm that the receiving part actually uses the selected 2BA or M3 standard. Small threads are sensitive to flow, first-layer expansion, material flexibility and barrel tolerances. Remove strings and support residue, verify the selected fit and print a short test. Adjust the fit option or small XY compensation before changing the scale of the complete model.
08What is the optional Ø 2 mm hole for?
It is a transverse tool hole just above the selected thread, similar to the hole found on many conventional shafts. A small pin or shaft tool can pass through it to provide controlled leverage while fitting or removing the shaft. Do not apply excessive torque to a printed prototype.
09How does the flight profile editor work?
X is the position along the flight and Y is the radial distance from the shaft centre. Points can reach Y = 0. Select a point without moving it to enter exact X, Y and corner-radius values, or drag it for quick shaping. The 3D flight and merged-system previews update from the same profile.
10Does the generator create a real STL?
Yes. Manifold generates a closed shaft-and-flight mesh in the browser and the app exports it as a binary STL in millimetres. Always inspect the sliced result for unsupported areas, missing detail and unexpected wall generation before printing.
11Can I save or share my design?
Yes. Use the PROJECT tab to download or import a JSON project. Copy Share Link creates a URL containing the complete shaft and flight configuration. Gallery projects can also be loaded into the editor and adapted.
12Does any model data get uploaded?
No. Geometry generation, previews and STL export run locally in the browser. A shared project is encoded into the URL itself.
13Can I create a configuration that does not make practical sense?
Yes. The configurator can generate a technically valid model from combinations that may still be too thin, too flexible, badly balanced, difficult to support or unsuitable for your printer and material. A successful preview or STL export does not prove that the part is useful, durable or safe. Use common sense and engineering judgement, inspect every transition in 3D and in the slicer, and print one controlled prototype before considering further use.
14How do I get a cleaner surface finish?
Allow the part to cool fully before removing the raft and supports. Cut strings and support remains with a sharp, controlled tool, then use fine sandpaper gently on rough edges and rigid transition areas. Work progressively and remove very little material around the selected thread and thin wings. TPU can fuzz, stretch or soften from friction, so sand slowly with light pressure and stop if the surface becomes warm.