3D printers follow physics. Following a few rules makes parts stronger and cheaper.
Wall thickness
Very thin walls can break or fail to print. As a rough guide for FDM, keep walls at least about a millimetre or two thick, and thicker where the part carries load.
Overhangs and supports
Angles steeper than about 45 degrees from vertical usually print without support. Flat bridges and steep overhangs need support, which adds time and marks. Tilting a part or adding a chamfer often removes the need.
Holes and fits
Printed holes come out slightly smaller than designed. When a part must fit another, leave a small clearance, typically a few tenths of a millimetre, and test with a small sample first.
Text and fine detail
- Raised text is more reliable than very thin engraved text.
- Use a bold font and keep letter strokes thick enough for the nozzle.
- Tiny details smaller than the nozzle width will not print.
Orientation
Place the part so the strongest direction follows the layers, and the flattest face sits on the bed for a smooth bottom.
Round the corners
Sharp inner corners concentrate stress. Small fillets make parts stronger.
Print a test first
For anything that must fit or carry weight, print a small test piece. It is cheap and avoids waste.
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