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Design Consideration

1. Avoid designing "Thin Wall"
   • Tip size: Typical FDM tip size is 0.012-0.025" (12,16,20,25 mils).
   • Slice Thickness: The recommended slice thickness depends on the tip size. It usually falls in the range between the tip size minus 0.005" to the tip size plus 0.002". E.g. for a 12 mils tip size, the recommended road width is in the range 0.007-0.014", say 0.01".
   • Road width: Usually is recommended as TWICE of the slice thickness. e.g., for road width of 0.010", road with is 0.02".
   • Thin wall: Usually is recommended AT LEAST TWICE of the road width. E.g. for a 0.010 slice, at least 0.04" (or larger) of wall thickness is recommended.

    

2. Orientation: Part orientation is critical for the following considerations
   • Surface Quality:
     • Build direction - The step-wise shape along the build-direction characterize the surface quality which is mainly determined by the slice thickness.
     • Top-bottom surface - determine by the "fill patterns" use to file the surface.
     Therefore, if yoou have large slice thickness and complex geometry, try to avoid placing high quality surfaces perpendicular to the build direction.
   • Part Integrity: The FDM part has a weaker strength in the slice direction. Therefore, for certain features that might exert forces in the slice layer direction, try to avoid the build orientation that might create easy-shearing (or delamination) in those features.
   • Build Time: The build time is mainly determined by the build-height. Therefore, to shorten the build time, orient the part to shorten the build height.
   • Support: Orient the part, so that the support structure can be minimized to shorten the build time, and increase surface quality.

    

   Hence, quality versus build time/cost is the main tade-off.