Key principles.
Affects everything
Build orientation determines surface finish, mechanical properties, support needs. Plan deliberately.
Metal yes, polymer no
SLS/MJF: powder supports part, no supports needed. DMLS: requires support structures for overhangs.
Hollow parts
Powder must escape from hollow parts. Drain holes (3-5 mm minimum) required.
0.5-1 mm
Minimum walls: SLS 0.8 mm, MJF 0.5 mm, DMLS 0.5 mm. Practical considerations vary.
5:1 typical
Tall thin features 5:1 aspect typical. Above this risks distortion during build.
Bead blast, polish
Standard finish: rough as-built. Bead blast for matte, vapor smooth (some materials), or CNC for tight tolerance.
FAQ
Complex geometry impossible to machine. Topology-optimized lightweight parts. Lattice structures. Custom anatomical implants.
SLS/MJF: ±0.2 mm typical. DMLS: ±0.2 mm. Post-machining critical features achieves ±0.025 mm.
SLS/MJF: PA12 (most common), PA11, TPU, glass-filled. DMLS: titanium, Inconel, aluminum, stainless 316L.
For complex geometry: powder bed often cheaper. For simple geometry at volume: CNC cheaper.
Z-direction (between layers) typically 80-90% of X/Y direction strength. Orient parts considering load direction.
As-built Ra 5-15 µm typical. Smoother after bead blast (Ra 3-6 µm). Critical features: post-machining.
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