A model that looks fine on screen can print poorly. A few design choices make the difference between a usable part and a failed print.
1. Wall thickness
Too thin and walls warp or fail; we keep load paths above the minimum for the chosen material and process.
2. Orientation
Print direction sets strength and surface finish. Layer lines are weakest across the build direction — we orient around the load.
3. Overhangs and supports
Steep overhangs need supports, which cost time and leave marks. Small chamfers often remove the need entirely.
4. Tolerances and fit
Holes shrink, mating parts need clearance. We tune fits per material rather than trusting nominal CAD dimensions.
5. Material choice
PLA, PETG, nylon and tough resins behave very differently. The right one depends on load, heat and finish, not just colour.