What are the common CAD errors that affect 3D printing quality and how to avoid them?

1 Wrong file format

One of the first things you need to check before sending your CAD model to a 3D printer is the file format. Not all 3D printers support the same formats, and some of them may require specific settings or conversions. For example, STL is a widely used format for 3D printing, but it only contains the surface information of your model, not the color, texture, or material. If you want to print a full-color model, you may need to use a different format, such as VRML, OBJ, or 3MF. You can also use a slicer software to convert your CAD model into a format that your 3D printer can read, such as G-code.

3 Non-manifold geometry

Non-manifold geometry is a term that describes a CAD model that has errors or inconsistencies in its structure, such as holes, gaps, overlaps, or inverted normals. These errors can cause problems when 3D printing, because they make the model unclear or impossible to print. For example, if your model has a hole in its surface, the 3D printer may not know how to fill it or where to start and stop the extrusion. If your model has an overlap, the 3D printer may print two layers of material in the same place, creating a blob or a weak spot. To avoid non-manifold geometry, you need to check and fix your model before printing, using a CAD software or a mesh repair tool. You can also use a slicer software to preview how your model will be printed and detect any errors.

4 Unsupported overhangs

Unsupported overhangs are parts of your model that extend beyond the base or the previous layer, without any support from below. These parts can cause 3D printing issues, such as sagging, curling, or breaking. For example, if you want to print a model of a bridge, you need to add some supports under the arches, otherwise they will collapse or deform. To avoid unsupported overhangs, you need to design your model with 3D printing in mind, and avoid angles that are too steep or too horizontal. You can also use a CAD software to add supports to your model, or use a slicer software to generate them automatically.

5 Incorrect orientation

Incorrect orientation is a CAD error that affects 3D printing quality and how to avoid it by choosing the best position for your model on the print bed. The orientation of your model can affect the printing time, the material usage, the strength, and the appearance of your 3D print. For example, if you print a model of a cylinder vertically, you will use less material and time than if you print it horizontally, but you will also create more layers and seams that can affect the smoothness and accuracy of your print. If you print a model of a hook horizontally, you will create a stronger and more functional print than if you print it vertically, because you will avoid weak points and overhangs. To avoid incorrect orientation, you need to consider the shape, size, and purpose of your model, and use a slicer software to rotate and position it on the print bed.

6 Inadequate infill

Inadequate infill is a CAD error that affects 3D printing quality and how to avoid it by choosing the right amount and pattern of infill for your model. Infill is the internal structure of your 3D print, and it determines how solid or hollow it is. Infill can affect the weight, strength, durability, and appearance of your 3D print. For example, if you print a model of a vase with a low infill percentage, you will save material and time, but you will also create a weak and fragile print that can break easily. If you print a model of a gear with a high infill percentage, you will create a strong and robust print that can withstand stress and friction, but you will also use more material and time. To avoid inadequate infill, you need to consider the function and aesthetics of your model, and use a slicer software to adjust the infill percentage and pattern.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?