Designing for 3D printing isn’t just about creating a 3D model — it’s about understanding the capabilities and limitations of additive manufacturing. Whether you're working with FDM, SLS, or resin printing (SLA/DLP), optimizing your design for the printing process can make all the difference in quality, performance, and cost.
In this article, we share practical tips and expert insights from ONEDGE’s experience to help you design smarter for additive manufacturing.
1. Technology first
Each 3D printing technology has its own strengths and constraints. Before modeling anything, ask yourself:Is the part meant for visual validation, functional use, or final production? Will it be printed with FDM (filament), SLS (powder), or SLA/DLP (resin)? What are the mechanical, thermal, or aesthetic requirements?
For example:
→ FDM is ideal for fast prototypes and durable, functional parts.
→ SLS is perfect for complex geometries and no-support builds.
→ Resin (SLA/DLP) offers the best surface finish and detail, but may require more support and post-processing.
2. Design with support structures in mind
In many printing processes (especially FDM and SLA), overhangs and bridges will require support material. To minimize post-processing you should avoid overhangs greater than 45°, orient the model to reduce the need for supports on visible or critical surfaces and use chamfers or fillets instead of sharp 90° angles.
💡 Designing with support removal in mind saves time and reduces the risk of damaging the part.
3. Consider wall thickness and tolerances
Not all geometries that look great on screen will print well in real life. Some general rules:
→ Minimum wall thickness depends on the technology:
- FDM: ≥ 0,8 mm
- SLA/DLP: ≥ 0,5 mm
- SLS: ≥ 1 mm
→ Add reinforcing ribs or fillets to thin or fragile areas.
→ Consider clearances for moving parts or assemblies (typically 0.2–0.5 mm depending on the printer’s resolution).
💡 Avoid going too thin to prevent warping, especially in large flat surfaces.
4. Optimize for print orientation
The orientation of your model affect surface finish, strength (layer adhesion), support placement and ultimately print times.
For example: vertical orientation in FDM gives better detail on the sides, but weaker Z-axis strength.SLA parts should be tilted at 30–45° angles to reduce suction forces and improve quality.
💡 Choosing the right orientation is a balance of aesthetics, mechanical strength, and efficiency.
5. Simplify where possible
3D printing allows for complex geometries, but simplicity is still your friend:
→ Combine parts only when necessary: modularity can help with post-processing, painting, or maintenance.
→ Avoid unnecessarily dense infill: many prints are functional with 30–40% infill.
→ Use parametric modeling for easy updates and scalability.
→ Less complexity usually means fewer errors, faster printing, and lower costs.
6. Post-processing: plan beyond the print
→ Design flat surfaces for easier sanding or painting.
→ Include alignment features (like pins or slots) for multi-part assemblies.
→ For resin prints, anticipate support marks and UV curing requirements.
7. Prototype early, iterate often
One of the biggest strengths of 3D printing is fast iteration. Don’t wait for the “perfect” model: test, adjust, and improve.
💡 Start with a quick prototype to check fit and proportions. Refine geometry based on real-world feedback. Use each iteration as a step toward the final product.
Designing for 3D printing also means knowing its limits to transform them into strengths. From the choice of technology to the optimization of orientation, every detail counts to obtain a truly functional, efficient and production-ready result.
At ONEDGE we apply these principles every day, combining experience and experimentation to create custom solutions, from prototypes to small series.
Would you like to learn more tips, see 3D printing in action, and stay up-to-date on industry best practices?
👉 Follow us on Instagram and LinkedIn to enter the heart of additive manufacturing and not miss a single curve of the future.
