Guides
Practical DfAM guides, free to read.
The design rules we teach in courses and enforce in engagements — condensed into guides you can apply on today's part. No sign-up required.
FDM wall thickness
Minimum and recommended wall thickness for FDM 3D printing, by nozzle size and use case.
Read the guide 6 min readOverhang angles
Where the 45° overhang rule comes from, when it's wrong, and the chamfer, teardrop, and bridging techniques that let you design FDM parts with no supports at all..
Read the guide 8 min read3D printing tolerances
Realistic dimensional tolerances for FDM, SLA, SLS, MJF and metal AM.
Read the guide 8 min readChoosing the right 3D printing process, defensibly
A practical filter for choosing between FDM, SLA, SLS, MJF, metal PBF, binder jetting and DED.
Read the guide 5 min readThe DfAM checklist
A 30-point Design for Additive Manufacturing checklist covering process fit, geometry, orientation and strength, materials, and release.
Read the guide 9 min read3D printing materials compared
PLA vs PETG vs ABS vs ASA vs Nylon vs PC.
Read the guide 7 min readInfill density and patterns
How infill density and pattern affect 3D print strength, weight and print time.
Read the guide 8 min read3D printing supports
When 3D printing supports are required, support types (normal vs tree, soluble vs breakaway), interface settings for clean removal, and design techniques to eliminate supports..
Read the guide 7 min readPrint orientation and strength
Why FDM parts are weak across layers, how print orientation controls strength, surface finish and supports, and how to orient parts so loads run along layers, not across them..
Read the guide 7 min readSnap-fit and living hinge design for 3D printing
How to design cantilever snap-fits and living hinges for FDM: material choice, print orientation, deflection and strain limits, and the geometry that survives repeated flexing..
Read the guide 9 min readMetal AM design rules
Design rules for metal LPBF/DMLS: overhangs, residual stress, wall and channel minimums, powder escape holes, machining stock and heat treatment..
Read the guide 8 min readPart consolidation
Consolidate assemblies into single AM parts: which parts to combine, integrating joints, tolerance-stack benefits, and when not to consolidate..
Read the guide 9 min readPost-processing 3D prints
Post-processing 3D prints by process: support removal, bead blasting, tumbling, vapor smoothing, machining, dyeing, sealing watertight, and painting..
Read the guide 9 min readFastening 3D printed parts
Heat-set inserts, tapped holes, thread-forming screws and captured nuts for 3D printed parts: hole sizing, boss design and torque limits that hold..
Read the guide 9 min readLightweighting and lattice structures for additive manufacturing
When lattices pay off, lattice types (strut, gyroid/TPMS), the topology optimization workflow, process fit and powder/resin escape for lightweight AM parts..
Read the guide 9 min readWhen to switch from 3D printing to injection molding
When to switch from 3D printing to injection molding: break-even math, bridge tooling, and the draft, wall, and gate redesign the crossover forces..
Read the guide 8 min readSLA/DLP design rules
Design rules for SLA and DLP resin printing: hollowing, drain and vent holes, wall minimums, supports, orientation, and post-cure..
Read the guide 8 min readSLS/MJF design rules
Design rules for SLS and MJF nylon powder printing: wall minimums, escape holes, clearances, packing density, dimensional spread, and dyeing..
Read the guide 8 min readWarping
Why 3D prints warp: differential cooling and shrinkage, which materials are worst, plus design and process fixes for corner curl and lifting..
Read the guide 9 min readGetting a perfect first layer and rock-solid bed adhesion
Dial in first layer height, nozzle gap, bed prep, brims and rafts, and stop elephant foot for reliable FDM prints..
Read the guide 9 min readDimensional accuracy
Understand shrinkage, over-extrusion, and thermal error, then calibrate flow and steps and design with compensation for accurate FDM parts..
Read the guide 8 min readBridging
Learn how bridges work, how far FDM can span with cooling, and how to design gaps and chamfers that print clean without supports..
Read the guide 8 min readDesign for assembly
Design printed parts that assemble fast and correctly: lead-in chamfers, self-locating joints, fit clearances, snap-fit vs fastener choices and poka-yoke..
Read the guide 9 min readCost estimation
What drives a 3D-printed part's price: machine time, material and support waste, labor, amortized machine cost, orientation, nesting and process bands..
Read the guide 9 min readEnclosure design
Design 3D-printed electronics enclosures: walls, snap-fit vs screw bosses and inserts, PCB standoffs, lids, vents, cable ports and button fit..
Read the guide 8 min readFood-safe 3D printing
Is 3D printing food safe? Food-grade filament vs a food-safe part, layer-line bacteria, brass-nozzle contamination, sealing and heat limits..
Read the guide 9 min readDesigning large parts for 3D printing
Design large-format 3D prints: build-volume limits, splitting and joining with dovetails, pins and bolts, warp control and smart seam placement..
Read the guide 9 min readGD&T and drawings for 3D printed parts
GD&T for 3D printed parts: which tolerances AM holds, datum selection, calling out build orientation, and how a printed-part drawing differs..
Read the guideBeyond the guides
Turn rules of thumb into a repeatable skill.
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