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Why did this simulation pass? Was the part designed right all along or was it simply user abuse that caused it to fail? The answer is more complicated than it seems.

Of course the force on the end cap will vary depending on the mass of the entire body and the angle of impact incidence. I chose the 3 most common areas of impact based on the most abused GH3 end cap I could find.

In this case the type of plastic plays an important role in discovering the failure mode of the part. PC-ABS is a blend of Polycarbonate(PC) and ABS and varies based on PC:ABS concentration, recycled content concentration, quality of recycled content and manufacturer preferences.

Overall, a pure PC-ABS blend has a greater tensile strength than pure ABS and shares a similar high-strength and high impact resistance common to PC. According to the research paper Processing and Characterization Of Recycled Pc/Abs Blends with High Recycle Content, the yield strength of 50:50 pure PC:ABS is 51.78MPa while pure abs alone is 42.8MPa.

The stock yield strength of PC-ABS provided with Fusion360 is 54.4MPa. This would put the fusion360 PC-ABS on par with the 70:30 pure PC:ABS yield strength included in the study.

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