Design for additive manufacturing: 5 practical tips

1. Respect minimum wall thickness

Each process has a practical minimum — typically around 0.5–1 mm for SLA and SLS, and a little more for metal. Walls thinner than this warp, break or simply fail to print. When in doubt, go thicker; you can always refine later.

2. Use orientation to your advantage

Layer lines run perpendicular to the build direction. Orient features that need accuracy or smoothness so they aren't fighting the layer direction. For SLS, orientation barely matters (no supports); for SLA, it changes surface quality and support removal.

3. Design out supports where you can

Overhangs above roughly 45° need support in SLA and metal printing. Redesigning a bracket, adding a small fillet, or splitting a part can remove supports entirely — improving surface quality and cutting finishing time.

4. Embrace consolidation

Additive manufacturing lets you merge multi-part assemblies into one. Fewer assemblies means fewer fasteners and less assembly labor. This is where metal 3D printing and SLS shine for end-use parts.

5. Choose the material for the job

Detail calls for SLA resin; function calls for nylon or metal. Picking the right material early avoids re-prints. See the full material library for options.