10 Design Tips for Better 3D Printed Parts

A good 3D print starts before the file reaches the printer. Small changes to geometry can improve strength, reduce support material, shorten print time and make assembly easier.

10 practical tips

1. Choose the build direction early. Orientation affects strength, supports and surface finish.
2. Use sensible wall thickness. Extremely thin walls can become fragile or difficult to print.
3. Add fillets where stress concentrates. Rounded transitions can improve durability.
4. Avoid unnecessary supports. Rework geometry or orientation where possible.
5. Design holes for the process. Small holes may print differently from their nominal CAD dimensions.
6. Allow assembly clearance. Mating parts need practical tolerance rather than zero-gap CAD fits.
7. Consider overhangs. Steep unsupported surfaces may need support or a revised angle.
8. Keep critical dimensions accessible. Avoid placing precision features where they are difficult to measure or finish.
9. Think about post-processing. Leave access for support removal, sanding, inserts or finishing.
10. Prototype the interface first. If a part must fit another component, print a small test section before committing to the full part.

Design for the actual process

FDM and SLA have different capabilities, so a design that works well for one process may need changes for another. Tell your manufacturer what the part needs to achieve, not just the desired dimensions.

HyCube Works can review a design before manufacturing when the application calls for specific fit, strength or finish requirements.