{"id":16,"date":"2025-04-02T09:19:02","date_gmt":"2025-04-02T09:19:02","guid":{"rendered":"http:\/\/tenco-ddm.com\/?page_id=16"},"modified":"2026-07-08T10:40:40","modified_gmt":"2026-07-08T09:40:40","slug":"design-for-additive-manufacturing","status":"publish","type":"page","link":"https:\/\/www.tenco-ddm.com\/en\/design-for-additive-manufacturing\/","title":{"rendered":"Design & Engineering"},"content":{"rendered":"

Design & Engineering<\/h1><\/div><\/div><\/div><\/div><\/div>

Tenco designs functional, production-ready 3D-printed parts with a focus on strength, detail, and smart use of additive manufacturing.<\/h2>\n

Tenco’s DfAM service helps engineering teams in Belgium and across Europe design parts that are optimised for additive manufacturing \u2014 from the first concept to series production.<\/p>\n

At Tenco, we help you turn innovative ideas into valuable applications. Design is more than just shaping an object \u2014 it\u2019s about integrating functionality, ergonomics, and meeting industrial standards. With every project being unique, close collaboration is key. From initial concept to final production, we\u2019re with you every step of the way.<\/p>\n<\/div><\/div><\/div>

\"Design<\/span><\/div><\/div><\/div>
\"Design<\/span><\/div><\/div><\/div>
\"Design<\/span><\/div><\/div><\/div>
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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 optimised for strength, durability, and cost-effectiveness \u2014 right from the start.<\/p>\n<\/div><\/div><\/div>

Design Guidelines for Additive Manufacturing<\/span><\/h3>\n<\/div><\/div><\/div>

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.<\/span><\/h2>\n<\/div><\/div><\/div>

Structural Considerations<\/h3>\n<\/div><\/div><\/div>

Wall Thickness<\/h4>\n

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.<\/p>\n<\/div><\/div><\/div>

Overhangs and Bridges<\/h4>\n

Limit overhang angles to 45\u00b0 or less to reduce the need for supports. Horizontal bridges should be kept short, preferably under 10 mm.<\/p>\n<\/div><\/div><\/div>

Supports and Rafts<\/h4>\n

Design with self-supporting geometries where possible. When supports are required, ensure they\u2019re easy to remove without damaging the part.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

Detail and Tolerances<\/h3>\n<\/div><\/div><\/div>

Detail Size<\/h4>\n

Fine features should exceed the minimum printable size: ~0.5 mm for FDM, 0.2 mm for SLA, and 0.3 mm for SLS.<\/p>\n<\/div><\/div><\/div>

Tolerances<\/h4>\n

Include clearance for fit and assembly \u2014 typically 0.2 mm to 0.5 mm, depending on the printer\u2019s precision.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

Part Orientation and Build Direction<\/h3>\n<\/div><\/div><\/div>

Orientation Optimisation<\/h4>\n

Position parts to reduce support material and maximise structural strength in critical areas. Remember that AM parts are anisotropic, meaning strength varies by build direction.<\/p>\n<\/div><\/div><\/div>

Layer Height<\/h4>\n

Choose the right layer height for your needs: thinner layers give better surface finish but increase build time.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

Surface Finish and Post-Processing<\/h3>\n<\/div><\/div><\/div>

Surface Quality<\/h4>\n

If a smooth finish is needed, design with post-processing in mind (e.g., sanding, polishing, or coating).<\/p>\n<\/div><\/div><\/div>

Text and Labels<\/h4>\n

Embossed or engraved text should be at least 0.5 mm deep\/high for clear visibility after printing and finishing.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

Complex Geometries and Lightweight Structures<\/h3>\n<\/div><\/div><\/div>

Complexity by Design<\/h4>\n

Leverage AM\u2019s ability to produce complex geometries that are difficult \u2014 or impossible \u2014 to achieve with traditional manufacturing.<\/p>\n<\/div><\/div><\/div>

Weight Reduction<\/h4>\n

Use internal lattice structures or optimised infill to minimise weight while maintaining mechanical strength.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

Material-Specific Considerations<\/h3>\n<\/div><\/div><\/div>

Material Properties<\/h4>\n

Always design with the selected material\u2019s properties in mind, such as flexibility, thermal resistance, or tensile strength.<\/p>\n<\/div><\/div><\/div>

Shrinkage and Warping<\/h4>\n

Consider shrinkage factors and warping risks, particularly for large parts or high-temperature materials.<\/p>\n<\/div><\/div><\/div><\/div><\/div>

FAQ for Design for Additive Manufacturing<\/span><\/h2>\n<\/div><\/div><\/div><\/div><\/div>

<\/i><\/i><\/span>What are the most important design rules for additive manufacturing?<\/span><\/a><\/h4><\/div>
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There are general guidelines applicable to AM, though they vary by technique. The correct starting point is always your application and its material requirements, since the material determines the printing process.<\/p>\n

Polyamide (PA), for example, is typically produced via SLS \u2014 so the relevant SLS design guidelines should be applied from the outset. Skipping process selection and going straight to printing is one of the most common and costly mistakes.<\/p>\n<\/div><\/div><\/div>

<\/i><\/i><\/span>How should wall thickness be approached when designing for 3D printing?<\/span><\/a><\/h4><\/div>
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Maintain consistent wall thickness throughout the part to avoid weak points. Minimum wall thickness depends on the material and technology \u2014 as a general rule, 0.8 mm applies to plastics and 1.0 mm to metals. Walls that are too thin risk warping or cracking; walls that are too thick waste material and can introduce internal voids.<\/p>\n<\/div><\/div><\/div>

<\/i><\/i><\/span>How should wall tolerances be applied when designing for 3D printing?<\/span><\/a><\/h4><\/div>
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Always include clearance for fit and assembly \u2014 typically 0.2 mm to 0.5 mm, depending on printer precision, printing technique, material, and application. For SLS, tolerances of 0.03 mm are commonly achieved; with DLP, tolerances as tight as 0.02 mm are attainable.<\/p>\n<\/div><\/div><\/div>

<\/i><\/i><\/span>What common design mistakes cause print failures or poor mechanical performance in additive manufacturing?<\/span><\/a><\/h4><\/div>
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