1. Orient for the load, not the print
Layer adhesion is weaker than the bulk material. Orient the part so primary loads run along the layers, not across them.
2. Round sharp internal corners
Stress concentrations at sharp internal corners cause early fatigue failure. A 0.5 mm fillet is almost free in print time and pays back in part life.
3. Self-supporting overhangs
Below 45° from vertical, FDM and SLA need support material. Chamfer the overhang or split the part.
4. Hollow with drain holes
SLA parts trap resin in hollow cavities. Add 4 mm drain holes to let it escape — saves material and reduces weight.
Get a quote
Plain-English guides on choosing the right 3D printing technology, material selection and design for additive manufacturing.