Design & Engineering

Tenco designs functional, production-ready 3D-printed parts with a focus on strength, detail, and smart use of additive manufacturing.

At Tenco, we help you turn innovative ideas into valuable applications. Design is more than just shaping an object – it’s about integrating functionality, ergonomics, and meeting industrial standards. With every project being unique, close collaboration is key. From initial concept to final production, we’re with you every step of the way.

Our proven experience in Design for Additive Manufacturing (DfAM) allows us to deliver the full range of AM benefits, often in combination with complementary production techniques. We take into account both creative design possibilities and the technical constraints of each additive technology. Our in-house expertise ensures your design is optimized for strength, durability, and cost-effectiveness – right from the start.

Design Guidelines for Additive Manufacturing

Each AM technology comes with its own capabilities and limitations. Designing for AM requires understanding the layer-by-layer nature of the process, which differs fundamentally from subtractive manufacturing. To avoid issues like warping, poor surface quality, or excessive support structures, specific design strategies must be applied.

Structural Considerations

Wall Thickness

Maintain consistent wall thickness to avoid weak points. Minimum wall thickness depends on the material and technology: typically 0.8 mm for plastics and 1.0 mm for metals.

Overhangs and Bridges

Limit overhang angles to 45° or less to reduce the need for supports. Horizontal bridges should be kept short – preferably under 10 mm.

Supports and Rafts

Design with self-supporting geometries where possible. When supports are required, ensure they’re easy to remove without damaging the part.

Detail and Tolerances

Detail Size

Fine features should exceed the minimum printable size: ~0.5 mm for FDM, 0.2 mm for SLA, and 0.3 mm for SLS.

Tolerances

Include clearance for fit and assembly – typically 0.2 mm to 0.5 mm, depending on the printer’s precision.

Part Orientation and Build Direction

Orientation Optimization

Position parts to reduce support material and maximize structural strength in critical areas. Remember that AM parts are anisotropic, meaning strength varies by build direction.

Layer Height

Choose the right layer height for your needs: thinner layers give better surface finish but increase build time.

Surface Finish and Post-Processing

Surface Quality

If a smooth finish is needed, design with post-processing in mind (e.g., sanding, polishing, or coating).

Text and Labels

Embossed or engraved text should be at least 0.5 mm deep/high for clear visibility after printing and finishing.

Complex Geometries and Lightweight Structures

Complexity by Design

Leverage AM’s ability to produce complex geometries that are difficult – or impossible – with traditional manufacturing.

Weight Reduction

Use internal lattice structures or optimized infill to minimize weight while maintaining mechanical strength.

Material-Specific Considerations

Material Properties

Always design with the selected material’s properties in mind – such as flexibility, thermal resistance, or tensile strength.

Shrinkage and Warping

Consider shrinkage factors and warping risks, particularly for large parts or high-temperature materials.