FDM is excellent for functional prototypes and end‑use parts - but it rewards designs that respect layer mechanics.
1) Start with wall thickness (then add ribs)
- For parts that see load, thicker isn’t always better. Use a sensible wall thickness first, then add ribs where stiffness matters.
- Thin walls can print fine but will flex and crack along layer lines under repeated stress.
2) Use fillets to kill stress risers
Sharp corners concentrate stress and become crack starters. Add fillets to inside corners, especially where ribs meet walls.
3) Design for the print orientation you actually need
Layer adhesion is usually the weakest axis. If the part will be pulled in one direction, design so the layers run across that load path, not parallel to it.
4) Holes and bosses: give them support
If a screw will bite into plastic, a boss with adequate diameter and wall support beats a hole in a thin wall every time.
5) Quick checklist before you request a quote
- Target material and operating temperature
- Load direction and any impact risk
- Critical fits and tolerances
- Finish expectations (raw, sanded, primed, painted)
If you want us to sanity-check printability and cost, send your CAD with a short brief.