Simply. Better. Design.
10 tips for
reliable design.
Simply. Better.
Design.
10 tips for
reliable
design.
1. Wall thickness and pins
= Distance between inner and corresponding outer surface
Wall thickness in X/Y direction → Rule of thumb Wall thickness > 0.6 mm
EOS P760/770 = approx. 0.6 mm
FORMIGA P110 = approx. 0.45 mm
Reproducible dimensions and mechanical properties = 1.5 mm
Wall thickness in Z direction → Rule of thumb: 3x layer thickness
EOS P760/770 = approx. 0.4 mm
FORMIGA P110 = approx. 0.3 mm Minimum
Pin thickness = 0.8 mm Minimum pin thickness for reproducible measurements and mechanical properties = 1.8 mm
2. Corners and edges
- Avoid 90° angles on components – 45° is better
- Faces and sharp edges should not taper to zero
- Sharp edges should have a minimum wall thickness
- Where possible, sharp edges should always be rounded (minimum radius 0.5 mm)
3. Internal channels
Powder residues must always be completely removed when reworking. Cleaning is difficult in the following cases:
- Long and thin channels
- Components with integrated channels that are difficult to access
- Parts with complex internal structures
Minimum diameter: 6 mm
The longer the channels, the larger the diameter should be.
We are only satisfied when we have found the best solution for you!
That is why close communication with you is very important to us and thinking outside the box is a matter of course.
We look forward to hearing from you!
4. Thermal distortion
- Applies primarily to long, large and thin areas – avoid these or increase wall thicknesses
- Avoid combining very thin and very thick structures, as temperature differences can also lead to warping.
5. Material savings/waste
- Save material where it is not needed
- Solid components result in high thermal stress
- Avoid closed cavities or drill holes for powder removal (∅ min. 10 mm)
- Minimisation of the total volume possible through lightweight structures
6. Layer construction (staircase effect)
The layer formation depends on the angle and has a significant influence on the surface.
- At angles < 20° to the X/Y plane, steps are clearly visible on the surface
- The steeper the angle, the finer the steps
- The step formation indicates the direction in which a component was manufactured
- The visibility of the steps also depends on the layer thickness
7. Joints
- Gap dimensions for joints: - X/Y: 0.3 mm–0.5 mm - Z: 0.5 mm–0.6 mm
- Our recommendation: 0.3–0.5 mm (if the gaps are too narrow, the joint may no longer be able to move because the walls merge together)
- Large joints are rather problematic because they generate more heat, which heats up any powder trapped inside
8. Fonts
Our recommendation to ensure details and lettering are successfully reproduced:
- Min. 14 pt (approx. 5 mm) font size - font height > 1 mm (for bold type)
- Type depth: > 0.6 mm (for embossed type)
- Line width: > 1 mm (for illustrations)
- Sans serif font
→ Any number (!) of characters and illustrations can be applied to the component at no extra cost.
9. Tolerances
- When designing SLS parts, symmetrical tolerances must be used
- The component should be drawn in the middle of the tolerance limits
- For loose connections, a gap dimension of at least 0.1 mm should be observed
10. Machining rework
- Design for clamping surfaces and allow for the required oversize in the component
- Allow a diameter tolerance of 0.4-0.6mm for fits
- Allow for offset in the design
- Always mark surfaces to be machined on the drawing or CAD model (in colour).
What specific challenges can we solve together?
- Complex geometries
- Prototyping
- Large scale printing
- Food compliance
- Lightweight structures
- SLS, FLM, DLP, VFGF
- ... other challenges? Let's talk about them!
*Schedule a free and non-binding consultation with our material and application experts to discuss your individual challenges.
Download for you
10 rules for your perfect design
Use our compact know-how for your design: In our guide, we have compiled the most important tips and rules for selective laser sintering (SLS) – so that your components are not only printable, but also convincing in practice. Download now for free!
As fast as possible
Your drawing is ready and you know what you need?
Upload your CAD data, select the material and process and receive a customised quote in real time. From prototypes to functional components, you benefit from the latest technology and our many years of experience.
As individual as necessary
Need help with design or material selection?
Your needs first. Our expertise and experience will guide you to the right solution. Whether it is material selection, process engineering or challenges, our advice combines technical know-how with deep industry understanding.
