Xometry 3D Printing Design Guide
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Design Guide: Preparing a File for 3D Printing VERSI ON 2 .0 3 D PRI NT I NG GU I D E V 2 . 0 Table of Contents Technical Considerations....................................................................3 Preferred File Settings................................................................................3 STL File Resolution.......................................................................................4 Design Tips.............................................................................................5 Overlapping Geometry...............................................................................5 Minimum Thickness.....................................................................................5 Clearance Between Moving Parts.............................................................6 Confined Hollows.........................................................................................6 Fillets..............................................................................................................6 Lightweighting............................................................................................7 Build Volume..........................................................................................8 Resources at Xometry..........................................................................9 2 3 D PRI NT I NG GU I D E V 2 . 0 Technical Considerations Preferred File Settings STEP is our preferred CAD file format. Working with this parametric format allows our team to be more inventive creating support structures. However, we will work with just about any CAD format, including native SolidWorks, AutoCAD and PTC Creo (Pro/ENGINEER.) STL is the standard file type for our 3D Printing software. A mesh resolution of 0.01-0.03mm and a ≤0.016mm chord length produce an optimal STL file. To change your mesh resolution, while saving your file to STL, click on options and choose the resolution to coarse or fine. Customize the .stl output with manual changes to deviation & angle to fine tune the resolution for your part. N OT E : Keep in mind that higher resolution creates larger files, and recommended settings are given for a good mix of quality and file size. 3 3D PR INTING GUI DE V2 .0 — T ECHNI CA L CONSI DER A T I ON S STL File Resolution A mesh resolution of 0.01 to 0.03 mm generally produces a good-quality STL file. Reducing mesh resolution below this range does not necessarily mean that model accuracy is improved. As a rule of thumb, designs that have many contours or curved surfaces need a higher resolution than flat, geometric surfaces. To change mesh resolution while saving your file to STL, click on options to set the resolution to be coarse or fine. The STL file can also be customized with manual changes to the deviation and angle. Keep in mind that higher Low resolution resolutions create larger files. High resolution 4 3 D PRI NT I NG GU I D E V 2 . 0 Design Tips Overlapping Geometry Overlapping geometry will sometimes cause problems, being misinterpreted by printer software when being converted into 2D layers. To ensure proper interpretation, multiple bodies are always unified, merged or booleaned together. Example of overlapping geometry Cross section of model at left demonstrates possibility of data loss Unified/merged geometry Cross section of model at left demonstrates intact data Minimum Thickness It is recommended that the features of a design have a minimum thickness of 0.6 mm [.024 in]. N OT E : Xometry recommends >1 mm [.039 in] for loadbearing features. Example of a model design with thin features 5 3 D PRI NT I NG GUI DE V2 .0 — DESI G N T I P S Clearance Between Moving Parts A great feature of SLS and PolyJet 3D printing is the ability to print all-in-one assemblies that feature moving parts. For assemblies including moving parts, e.g. fine detail separation, Xometry recommends a clearance of >0.5 mm [.02 in]. Example model design of an all-inone assembly with moving parts Confined Hollows If a model design contains confined hollows, there is no way to remove the support material. Xometry recommends designing a model so that support material can be removed. This is especially important when printing moving parts and parts made from clear material. Limiting cavities that are confined to one opening will reduce cleaning time for support material, thus lowering Original model Model with holes added for removing support material the price of the build. Additionally, cavities having a depth of over 50.8 mm [2 in] with only one access point are not recommended. Fillets Adding fillets (rounded edges) to a design will strengthen unsupported surfaces and make parts more robust by distributing stress over a broader area. While Xometry’s PolyJet, SLS, and DMLS printers are capable of printing Original model 90° corners, fillets are recommended to add strength to any part. “Lollipop head” features, where a large mass connects to a much smaller mass, are especially prone to breaking, making them ideal candidates for fillets as well. Model with fillets added 6 3 D PRI NT I NG GUI DE V2 .0 — DESI G N T I P S Lightweighting Creating pockets in designs will reduce print material and making it more cost-effective to build. When creating a pocket, be sure to create an exit hole for un-sintered (SLS and DMLS) or support (PolyJet) material removal. Original model Model with lightweighting 7 3 D PRI NT I NG GU I D E V 2 . 0 Build Volume The maximum build volume of a part depends on the 3D printing technology used: • SLS: 13” x 13” x 20” (13” max dimension preferred) • FDM: 24” x 36” x 36” • PolyJet 3D: 19” x 15” x 7” • DMLS (Aluminum): 6” x 6” x 6” • DMLS (Stainless Steel): 9” x 6” x 6” Part built with SLS DMLS parts of various sizes FDM parts in progress 8 3 D PRI NT I NG GU I D E V 2 . 0 Resources at Xometry Online Instant Quoting Live Engineering Support Web: Upload your CAD file at get.xometry.com/quote Hours: M-F 8:00 AM - 9:00 PM EST CAD: Email: support@xometry.com Download the free Xometry Add-In for SOLIDWORKS: xometry.com/solidworks Phone: (240) 252-1138 Accepted File Types: .stl, .step, .stp, .x_t, .x_b, Online: xometry.com/support offers live chat, FAQs, .sldpart, .ipt, .prt, .sat, .catpart (max file size: 300MB) and other helpful articles. Capabilities: CNC Machining, Sheet Metal Fabrication, 3D Printing, Urethane Casting, Injection Molding ITAR Registered All uploads are secure and confidential. Contact us for assistance with large orders and existing Xometry quotes. Need to use a PO? We offer same day credit application processing. Contact us for details. 9
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