Design for Production-Grade Results

3D Design Guidelines

Designing parts for production-grade 3D printing requires consideration of material behaviour, structural integrity, and manufacturing constraints. Following these guidelines helps ensure parts are strong, dimensionally accurate, and repeatable, while reducing the need for redesign or rework.

These principles apply across most engineering plastics and additive manufacturing processes.

If you are unsure whether your design is suitable, we can review your CAD files and recommend adjustments before production.

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Minimum Wall Thickness

Wall thickness directly affects part strength, durability, and print reliability.

Recommended minimum: ≥ 1.2 mm

Walls thinner than this may:

  • Lack structural strength
  • Warp during cooling
  • Print inconsistently
  • Fail under load or handling

Thicker walls improve rigidity and dimensional stability, particularly for functional or load-bearing components.

Overhang Angle

Overhangs are surfaces that extend outward without support underneath.

Recommended maximum overhang: 45°

Surfaces exceeding this angle may:

  • Require support structures
  • Show reduced surface quality
  • Increase print time and post-processing

Designing within this range improves surface finish and production efficiency.

Fillets Improve Strength and Reliability

Sharp internal corners create stress concentration points, increasing the risk of cracking or failure.

Recommended fillet radius: ≥ 1 mm

Fillets help to:

  • Distribute mechanical stress more evenly
  • Improve part strength
  • Enhance durability
  • Improve print consistency

Rounded transitions also support smoother material flow during printing.

Clearance Between Moving or Mating Parts

Clearance ensures parts that must fit together or move relative to each other function correctly.

Recommended minimum clearance: ≥ 0.3 mm

Insufficient clearance may cause:

  • Binding or friction
  • Parts fusing together during printing
  • Assembly difficulties

Proper clearance allows reliable assembly and functional performance.

Build Orientation Matters

The orientation of a part during printing affects strength, surface finish, and dimensional accuracy.

Proper orientation can:

  • Improve mechanical strength in load-bearing directions
  • Reduce the need for support structures
  • Improve surface finish on critical faces
  • Increase production consistency

Build orientation is an important factor in achieving production-grade results.