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3D Model Design Guide

Design to these rules and your parts print and machine right the first time, with more accurate quotes.

Values are typical references; our engineers review every order. For tighter requirements, add a note when ordering or attach a 2D drawing.

General rules

Whatever the process, make sure your files meet these first.

ItemRequirement
File formats3D printing: STL, OBJ, STEP. CNC machining: STEP only (.stp / .step)
UnitsSTL and OBJ files carry no units and are read as millimeters. If you modeled in cm or inches, change the model unit after uploading
File sizeUp to 20MB per file. Simplify very dense STL meshes first
Watertight meshMeshes must be closed, with no holes, flipped normals, self-intersections or overlapping faces
Multiple partsExport each part as its own file. Do not upload a whole assembly as one file
Max size3D printing: 600 × 600 × 400 mm per part. Larger parts are printed in sections and bonded or assembled

3D printing

Each process resolves a different level of detail. Check your material against this table.

ItemSLA resinSLS / MJF nylonFDM filamentMetal AlSi10Mg
Min. wall thickness0.8 mm1.0 mm1.2 mm1.0 mm
Min. detail (embossing, text)0.3 mm0.5 mm0.8 mm0.4 mm
Accuracy±0.1 mm or ±0.2%±0.2 mm or ±0.3%±0.3 mm±0.1 mm or ±0.2%
Min. hole diameter1.0 mm1.5 mm2.0 mm1.0 mm
Fit clearance0.2 mm0.3 mm0.4 mm0.2 mm
Overhangs & supportsSupports above 30°, leaving marksNo supports neededSupports above 45°Supports above 45°, removed in post-processing
Hollow parts2+ drain holes of Ø3 mmPowder escape holes, Ø5 mm+Infill can be setPowder escape holes, Ø5 mm+

Illustrated

Wall ≥ 0.8 mmToo thin
Wall thicknessWalls that are too thin fail to print or snap easily. Follow the minimum for your process.
> 45°Support
Overhangs & supportsFaces that overhang too far from vertical need supports, which leave marks once removed.
Gap 0.2–0.4 mm
Fit clearanceParts that fit together, like shafts in holes or snap fits, need a gap between them.
Drain hole ≥ Ø3 mm
Drain holesWithout holes, resin or powder stays trapped inside, adding weight or cracking the part.
  • SLA resinThe smoothest surface, ideal for cosmetic parts. Large flat panels can warp, so add ribs or hollow them.
  • SLS / MJF nylonNo supports, so complex internal features and living hinges work. Even matte finish.
  • FDM filamentLowest cost, with visible layer lines. Align loads with the layers; parts break most easily between layers.
  • Metal AlSi10MgGood for conformal channels and lightweight lattices. Leave stock on mating faces and threads for machining.

CNC machining

CNC cuts from the outside in with round tools, which shapes what inner corners, deep pockets and holes can look like.

ItemRecommendation
Inner cornersSharp inner corners are impossible; add a radius at least the tool radius, ideally 1/3 of the pocket depth
Pocket depthNo more than 4× the tool diameter. Deeper pockets need long tools and cost more
Min. wall thicknessMetal 0.8 mm, plastic 1.5 mm. Tall thin walls chatter and deform
HolesDepth up to 4× the diameter. Use standard drill sizes (e.g. Ø3, Ø4, Ø5 mm)
ThreadsSelect threads in the configuration and state the size (e.g. M4×0.7) in the note or drawing. Thread depth up to 3× the diameter
Tolerances±0.1 mm by default. For tighter tolerances, attach a 2D drawing with callouts
TextEngraved (recessed) text 0.3–0.5 mm deep, at least 2 mm tall, in a sans-serif font

Illustrated

ToolR ≥ tool radius
Inner corner radiusRound tools cannot cut sharp inner corners. Make the radius at least the tool radius.
Tool ØDepth ≤ 4 × tool Ø
Pocket depthDeep pockets need long tools, which chatter and leave a poor finish.
Hole ØDepth ≤ 4 × hole Ø
Hole depthDeep holes clear chips poorly and break drills.
MKHeight ≥ 2 mm0.3–0.5 mm deep
Engraved textEngraved text machines more easily than raised text; thin strokes are too narrow for the tool.

Checklist

Run through this before uploading to save a round of revisions.

  • Units are correct: the model matches the real-world size
  • The mesh is closed, with no holes or flipped normals
  • Walls meet the minimum thickness for your process
  • Parts fit the build volume, or have been split
  • Mating parts have clearance between them
  • Hollow parts have drain or powder escape holes
  • CNC parts have radiused inner corners and no overly deep pockets
  • Threads, tolerances and other requirements are in the note or a 2D drawing

FAQ

Why are the dimensions in my quote different from my model?

Usually units. STL and OBJ files store no units and are read as millimeters. If you modeled in cm or inches, change the model unit on the configuration page and the size and price are recalculated.

My model is bigger than the printer. What now?

The max 3D printing size is 600 × 600 × 400 mm per part. Split larger models into sections with locating features, then bond or bolt them together after printing, or contact us for a review.

Can you print moving parts?

Yes. SLS / MJF nylon needs no supports, so print-in-place hinges and chains work. Leave at least 0.3 mm between moving parts.

Will supports leave marks?

SLA, FDM and metal prints show marks where supports touched, which can be sanded. Orient cosmetic faces upward or mention them in your note.

How do I fix a broken STL?

Use the mesh repair in your CAD software, or a free tool such as Meshmixer or Microsoft 3D Builder, then export again.

Can CNC make sharp inner corners?

Milling cannot. If you need a square corner, add a dog-bone relief or ask for wire EDM, and say so in your note.

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