5 Design Tips for Efficient, Cost-Effective 3D Printing

The adoption of 3D printing at Accurate CNC has been an exciting journey for our Idaho machine shop. For our customers, this technology has enabled a variety of new use cases, from rapid prototyping to overnight production runs. And from our perspective, there's nothing quite like the thrill of tackling manufacturing challenges with brand-new equipment. Each project has brought opportunities to learn and innovate.

With our experience in 3D printing, we've gained valuable insights into helping customers optimize their projects for cost-efficiency, shorter lead times, and smoother production. By partnering with us early in your process, you’ll get the guidance you need to ensure success from the start. 

Here are five essential design tips to keep in mind for your next 3D printing project.

1. Minimize Overhangs and Bridges

Large overhangs and bridges present a common issue for the Fused Deposition Modeling (FDM) printers that we operate in our shop. The typical solution is to print supports for these features with your part and then remove them after printing. This can allow otherwise impossible geometries to be printed.

However, this decision comes with drawbacks. Support structures significantly increase print time, can add to your costs, and may leave surface imperfections when they are removed. 

We recommend you avoid overhangs greater than 45 degrees when possible. Instead, try to modify your design to reduce the need for support while maintaining functionality. Another option is to print your part in two pieces—read our next tip for guidance on that decision!

2. Consider Splitting Your Part

When parts are large or intricate, we often recommend splitting them into multiple pieces to be assembled post-printing. This approach can:

• Minimize support requirements

• Improve strength through optimal layer orientation (more on this in Tip 4)

• Ensure that parts fit within the printer’s build area

We’re here to guide you through the process, ensuring each section is designed for seamless assembly. For added stability, especially in rigid parts, we can insert pins along with adhesive for a stronger bond. This is a straightforward process, and while we offer more complex assembly services for other projects, 3D-printed part assembly is typically quick and efficient.

3. Add Relief to Threads in Your CAD Model

If your design includes printed threads, a slight modification in your CAD model will ensure better fit and function. We suggest adding between 0.003" and 0.005" of clearance to both male and female threads, a simple adjustment using CAD tools like Autodesk Fusion’s “Press Pull” feature. Proper thread relief avoids time-consuming manual adjustments, ensuring your parts fit together smoothly from the start.

4. Orient Your Layers for Strength

In FDM printing, layer line orientation is an important consideration. FDM printers create your parts layer by layer, with each printed layer adhering to the previous one. However, the bonds between layers are weaker than the continuous material within a layer. As a result, proper part orientation during printing is critical to a part’s strength and structural integrity.

For example, the images here show a 3D-printed coat hanger printed in different orientations. Printing it flat distributes the load more effectively across layers, strengthening the part. When printed upright, the structure relies on weaker layer bonds, which could compromise its load-bearing ability. Our team can help you choose the best orientation to maximize your part’s performance.

5. Round Your Part’s Corners

In a 3D-printed part, stress will concentrate at sharp corners, creating weak points where cracking may occur. The simplest solution is to round a corner by adding a radius to spread that stress across more material. 

If sharp corners are necessary for your part’s application, we can reinforce sharp corners to improve their strength. However, these workarounds typically require additional programming time and could impact costs.

Need Help With Your 3D Print Design? Let’s Talk!

Mastering these design principles will help you save time, materials, and costs on your next 3D printing project. If you have any other questions about additive manufacturing—or if you’d like to learn more about our other capabilities, like precision machining or laser engraving—our team is ready to help you make the most of your design.

Request a quote today and let Accurate CNC bring your ideas to life!