What are the most common design errors or mistakes that affect the 3D printing process and outcome?

1 Overhangs and supports

One of the most common design errors in 3D printing is creating overhangs that are too steep or too long. Overhangs are parts of the model that extend beyond the previous layer without any support. If the overhang angle is greater than 45 degrees, the print may sag, curl, or collapse. To avoid this, you can either add supports to your model or modify the design to reduce the overhang angle. Supports are additional structures that hold up the overhangs during printing, but they also increase the material usage, printing time, and post-processing work. Therefore, you should use supports sparingly and only when necessary.

3 Orientation and warping

The orientation of your model on the print bed can also affect the outcome of your 3D printing. Orientation refers to the direction and angle of your model relative to the print bed. The orientation can influence the print quality, accuracy, strength, and support requirements of your model. For example, if you print a model with a large flat base, you may face the problem of warping. Warping is when the edges of the base lift up from the print bed due to thermal contraction. To avoid warping, you can either use a heated print bed, apply an adhesive layer, or orient your model diagonally or vertically.

4 Resolution and layer height

The resolution of your 3D printing is determined by the layer height, which is the thickness of each layer of material that is deposited by the printer. The layer height affects the smoothness, detail, and speed of your print. If the layer height is too high, the print may look rough, coarse, or jagged. If the layer height is too low, the print may look smooth, fine, or detailed, but it may also take longer, use more material, and increase the risk of clogging or jamming. To avoid these problems, you should choose the appropriate layer height for your model based on its complexity, size, and purpose.

5 Tolerances and clearances

Tolerances and clearances are the gaps or spaces between the parts of your model that are meant to fit together or move relative to each other. For example, if you are printing a hinge, a gear, or a snap-fit joint, you need to consider the tolerances and clearances of the components. If the tolerances and clearances are too tight, the parts may not fit, move, or function properly. If the tolerances and clearances are too loose, the parts may be wobbly, noisy, or unreliable. To avoid these issues, you should measure and test the tolerances and clearances of your model before printing and adjust them according to the accuracy and shrinkage of your printer and material.

6 Material and settings

The last common design error in 3D printing is choosing the wrong material and settings for your model. Material and settings refer to the type and properties of the material that you use for printing and the parameters that you set for the printer, such as temperature, speed, flow, and cooling. Different materials and settings have different advantages and disadvantages for 3D printing, such as strength, flexibility, durability, color, and cost. If you choose the wrong material and settings for your model, you may encounter problems such as warping, cracking, stringing, or delamination. To avoid these problems, you should research and compare the different materials and settings that are compatible with your printer and model and choose the ones that best suit your needs and expectations.