Design for 3D Printing Toolkit
Get in-depth design advice to optimise 3D-printed parts. Designing with additive manufacturing in mind can accelerate production time and reduce overall cost.
Optimising Part Design
for 3D Printing
There are many design elements involved in creating plastic or metal parts for 3D printing—design for printability is a key one. At Protolabs, we provide automated design analysis on CAD models that highlights features in your part design that can be adjusted for manufacturability. To keep design advisories at a minimum and optimise part design, we created this helpful kit of 3D printing resources.
Designing for 3D Printing Processes
→ Stereolithography (SLA)
→ Selective Laser Sintering (SLS)
→ Multi Jet Fusion (MJF)
→ PolyJet
→ Metal 3D Printing
Navigating 3D Printing Advisories
→ Small Gap Minimums
→ Minimum Wall Thicknesses
→ Maximum Part Sizes
DMLS Sizes
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | ||
| Aluminium AlSi10Mg | N/A | N/A | 1.00mm | 1.00mm | 1.00mm | 1.00mm | DMLS |
| Cobalt Chrome | 1.00mm | 1.00mm | N/A | N/A | N/A | N/A | DMLS |
| Inconel 718 | N/A | N/A | 1.00mm | 1.00mm | 1.00mm | 1.00mm | DMLS |
| Stainless Steel 316L | 1.00mm | 1.00mm | 1.00mm | 1.00mm | N/A | N/A | DMLS |
| Maraging Steel | N/A | N/A | 1.000mm | 1.00mm | 1.00mm | 1.00mm | DMLS |
| Titanium Ti-6Al-4V | 1.00mm | 1.00mm | 1.00mm | 1.00mm | 1.00mm | 1.00mm | DMLS |
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | ||
| Aluminium AlSi10Mg | N/A | N/A | 0.5mm | 1.00mm | 0.50mm | 1.00mm | DMLS |
| Cobalt Chrome | 0.50mm | 1.00mm | N/A | N/A | N/A | N/A | DMLS |
| Inconel 718 | N/A | N/A | 0.50mm | 1.00mm | 0.50mm | 1.00mm | DMLS |
| Stainless Steel 316L | 0.50mm | 1.00mm | 0.50mm | 1.00mm | N/A | N/A | DMLS |
| Maraging Steel | N/A | N/A | 0.50mm | 1.00mm | 0.50mm | 1.00mm | DMLS |
| Titanium Ti-6Al-4V | 0.50mm | 1.00mm | 0.50mm | 1.00mm | 0.50mm | 1.00mm | DMLS |
| Micro/ Fine Resolution (mm) | High Resolution (mm) | Normal Resolution (mm) | Process | |
|---|---|---|---|---|
| Aluminium | - | 250 x 250 x 300 | 300 x 300 x 380 | DMLS |
| Stainless Steel 316 L | 71 x 71 x 80 (Ø100 x 80) | 250 x 250 x 300 | - | DMLS |
| Inconel 718 | - | 250 x 250 x 300 | 250 x 250 x 300 | DMLS |
| Maraging Steel | - | 250 x 250 x 300 | 250 x 250 x 300 | DMLS |
| Titanium | 71 x 71 x 80 (Ø100 x 80) | 250 x 250 x 300 | 250 x 250 x 300 | DMLS |
| Cobalt Chrome | 100 x 100 x 100 | - | - | DMLS |
SLA Sizes
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | ||
| ABS-Like Black | N/A | N/A | 0.13mm | 0.41mm | 0.25mm | 0.41mm | SLA |
| ABS-Like Grey | N/A | N/A | N/A | N/A | 0.25mm | 0.41mm | SLA |
| ABS-Like Translucent/Clear | N/A | N/A | 0.13mm | 0.41mm | 0.25mm | 0.41mm | SLA |
| ABS-Like White | N/A | N/A | 0.13mm | 0.41mm | 0.25mm | 0.41mm | SLA |
| Ceramic-Like (Advanced High Temp) | N/A | N/A | 0.13mm | 0.41mm | 0.25mm | 0.41mm | SLA |
| PC-Like Advanc High Temp | N/A | N/A | 0.13mm | 0.41mm | 0.25mm | 0.41mm | SLA |
| MicroFine™ Green | 0.07mm | 0.20mm | N/A | N/A | N/A | N/A | SLA |
| True Silicone | N/A | N/A | N/A | N/A | 0.25mm | 0.41mm | SLA |
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | ||
| ABS-Like Black | N/A | N/A | 0.40mm | 0.65mm | 0.50mm | 0.65mm | SLA |
| ABS-Like Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.65mm | SLA |
| ABS-Like Translucent/Clear | N/A | N/A | 0.40mm | 0.65mm | 0.50mm | 0.65mm | SLA |
| ABS-Like White | N/A | N/A | 0.40mm | 0.65mm | 0.50mm | 0.65mm | SLA |
| Ceramic-Like (Advanced High Temp) | N/A | N/A | 0.40mm | 0.65mm | 0.50mm | 0.65mm | SLA |
| PC-Like Advanc High Temp | N/A | N/A | 0.40mm | 0.65mm | 0.50mm | 0.65mm | SLA |
| MicroFine™ Green | 0.40mm | 0.40mm | N/A | N/A | N/A | N/A | SLA |
| MicroFine™ Grey | 0.40mm | 0.40mm | N/A | N/A | N/A | N/A | SLA |
| True Silicone | N/A | N/A | N/A | N/A | 0.50mm | 0.65mm | SLA |
| Micro/ Fine Resolution (mm) | High Resolution (mm) | Normal Resolution (mm) | Process | |
|---|---|---|---|---|
| ABS-Like Black (Accura Black 7820) | - | 247 x 247 x 250 | 247 x 247 x 250 | SLA |
| ABS-Like Translucent/Clear (WaterShed) | - | 247 x 247 x 250 | 736 x 635 x 533 | SLA |
| MicroFine™ Green | 127 x 127 x 63 | - | - | SLA |
| MicroFine™ Grey | 127 x 127 x 63 | - | - | SLA |
| PC-Like Advanc High Temp (Accura 5530) | - | 247 x 247 x 250 | 247 x 247 x 250 | SLA |
| Ceramic-Like (Advanc HighTemp PerFORM) | - | 247 x 247 x 250 | 585 x 585 x 380 | SLA |
| ABS-Like Grey (Accura Xtreme Grey) | - | - | 585 x 585 x 380 | SLA |
| ABS-Like White (Accura Xtreme White 200) | - | 247 x 247 x 250 | 736 x 635 x 533 | SLA |
| True Silicone | - | - | 70 x 130 x 100 | SLA |
SLS & MJF Sizes
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | ||
| PA 12 Smooth White | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| PA 12 Vapour Smooth White | N/A | N/A | N/A | N/A | 1.50mm | 1.50mm | SLS |
| PA 12 - Carbon Filled Smooth Black | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| PA 12 Flex Pure Black | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| TPU-88A Pure Black | N/A | N/A | N/A | N/A | 1.00mm | 1.00mm | SLS |
| PA 12 Smooth Light Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| PA 12-Glass Beads Smooth Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| PA 11 Smooth Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| PA 11 Vapour Smooth Black | N/A | N/A | N/A | N/A | 1.50mm | 1.50mm | MJF |
| Ultasint TM TPU-01 - 88A Pure Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| Ultasint TM TPU-01 - 88A Vapour Smooth Black | N/A | N/A | N/A | N/A | 1.50mm | 1.50mm | MJF |
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | ||
| PA 12 Smooth White | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| PA 12 Vapour Smooth White | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| PA 12 - Glass Filled Smooth White | N/A | N/A | N/A | N/A | 1.00mm | 1.00mm | SLS |
| PA 12 - Carbon Filled Smooth Black | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| PA 12 Flex Pure Black | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | SLS |
| TPU-88A Pure Black | N/A | N/A | N/A | N/A | 1.00mm | 1.00mm | SLS |
| PA 12 Smooth Light Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| PA 11 Smooth Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| PA 11 Vapour Smooth Black | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| Ultasint TM TPU-01 88A Pure Grey | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| Ultrasint TM TPU-01 88A Vapour Smooth Black | N/A | N/A | N/A | N/A | 0.50mm | 0.50mm | MJF |
| Micro/ Fine Resolution (mm) | High Resolution (mm) | Normal Resolution (mm) | Process | |
|---|---|---|---|---|
| PA 12 Smooth White | - | - | 676 x 367 x 564 | SLS |
| PA 12 Vapour Smooth White | - | - | 500 x 300 x 300 | SLS |
| PA 12 - Glass Filled Smooth White | - | - | 292 x 320 x 406 | SLS |
| PA 12 - Carbon Filled Smooth Black | - | - | 490 x 490 x 490 | SLS |
| PA 12 Flex Pure Black | - | - | 490 x 490 x 490 | SLS |
| TPU-88A Pure Black | - | - | 330 x 280 x 440 | SLS |
| PA 12 Smooth Grey | - | - | 284 x 380 x 380 | MJF |
| PA 11 Smooth Grey | - | - | 284 x 380 x 380 | MJF |
| PA 11 Vapour Smooth Black | - | - | 284 x 380 x 380 | MJF |
| UltrasintTM TPU-01 88A Pure Grey | - | - | 284 x 380 x 380 | MJF |
| UltrasintTM TPU-01 88A Vapour Smooth Black | - | - | 284 x 380 x 380 | MJF |
PolyJet & 3D Printed Silicone Sizes
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | Minimum Wall Thickness X/Y | Minimum Wall Thickness Z | ||
| 3D Printed Silicone | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet & 3D Printed Silicone |
| Digital Black | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Digital Clear/Translucent | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Digital Overmould | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Digital White | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Micro/Fine Resolution | High Resolution | Normal Resolution | Process | ||||
|---|---|---|---|---|---|---|---|
| Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | Minimum Small Gap X/Y | Minimum Small Gap Z | ||
| 3D Printed Silicone (60-65%) | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet & 3D Printed Silicone |
| Digital Black | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Digital Clear/Translucent | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Digital Overmould | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Digital White | N/A | N/A | N/A | N/A | 0.80mm | 0.80mm | PolyJet |
| Micro/ Fine Resolution (mm) | High Resolution (mm) | Normal Resolution (mm) | Process | |
|---|---|---|---|---|
| Digital Clear/ Translucent | - | - | 490 x 390 x 200 | PJET |
| Digital Black | - | - | Stratasys OBJET 500 Connex 3 - 490 x 390 x 200 Keyence AGILISTA 3200W - 297 x 210 x 200 |
PJET |
| Digital White | - | - | Stratasys OBJET 500 Connex 3 - 490 x 390 x 200 Keyence AGILISTA 3200W - 297 x 210 x 200 |
PJET |
| Digital Overmould | - | - | Stratasys OBJET 500 Connex 3 - 490 x 390 x 200 Keyence AGILISTA 3200W - 297 x 210 x 200 |
PJET |
| 3D Printed Silicone (60-65%) | - | - | 297 x 210 x 200 | 3DS |
3D-printed Parts on Your Schedule
Our lead time options lend you flexibility. Need printed parts lightning fast? Select Expedite at checkout. Not in a rush? Choose Economy to save on cost. For reliable delivery on-time, select Standard. Your parts when you need them.
