Design Element | Suggestions (Industry Standard Values) | Reasons and Benefits |
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Minimum Wall Thickness | Minimum thickness ≥ 0.8 - 1.2 mm | Ensures strength, reduces risk of deformation or print failure. |
Layer Height | Typical range: 0.1 - 0.3 mm (standard: 0.2 mm) | Balances print speed, resolution, and surface finish quality. |
Hole Diameter | Minimum hole diameter ≥ 1.0 - 2.0 mm | Guarantees accurate reproduction, prevents hole closure during printing. |
Support Structures | Minimize supports, orientation-dependent | Reduces material usage, simplifies post-processing, and improves surface finish. |
Overhang Angles | Maximum angle without supports: ≤ 45° | Prevents sagging, ensures quality, and reduces the need for supports. |
Bridging Distance | Maximum unsupported distance: ≤ 25 mm | Maintains structural integrity and avoids sagging or deformation. |
Text and Logos | Minimum depth/height ≥ 0.5 - 1.0 mm | Ensures clarity, readability, and print accuracy. |
Tolerances | Typical dimensional tolerance: ±0.2 - 0.5 mm | Reflects achievable accuracy, balancing precision with print speed and cost. |
Clearance Between Parts | Minimum recommended clearance: ≥ 0.4 mm | Allows movable assemblies, reduces risk of fusing or interference. |
Threaded Features | Use inserts or self-tapping threads if strength needed | Ensures strength, accuracy, and durability of threads. |
Chamfers & Fillets | Minimum radius/chamfer ≥ 0.5 mm | Improves printability, reduces stress concentrations, and enhances aesthetics. |
Part Orientation | Optimize for strength, minimal supports, and accuracy | Enhances mechanical properties, surface quality, and minimizes material usage. |
Internal Cavities | Use escape holes or support removal paths | Enables easy removal of support material and reduces post-processing complexity. |
Part Complexity | Complex shapes encouraged within limits | Leverages additive manufacturing’s strengths while ensuring print reliability. |