We were in the middle of recording when we had to stop because the servo arm on the Iron Man build snapped.
The servo bracket was one of the first parts we ever printed, before we even printed the helmet pieces. We used PLA at the time because that's where we were in the learning curve. Under load it didn't hold and one of the arms broke, so we reprinted in PETG. The heat set inserts had a similar problem from the same early print run. They were dropping right through the holes instead of gripping, which likely was a printer settings issue from that early stage. After reprinting both parts in PETG they seem fit the way they're supposed to and we got back to the actual build.
This kind of thing happens when you're building a long project over time. Parts from your early print days don't always survive contact with the rest of the build.
PETG is a great option for structural parts that need to hold up to real stress is just the right call.
Have you ever had to go back and reprint older parts on a project because your material or settings knowledge caught up to what the part actually needed?