Wall Thickness

The filament size is a limiting factor for wall thickness. If the features of the product that you want to make are thinner than twice the thickness of the filament, then the outcome of the print is not going to be good. If the walls are going to support certain structures, then the supposed thickness should be around 1.2 – 1.5mm.

Holes

It is usually advised that the diameter of the holes that are being created using the FDM technology should be kept greater than 1mm. This will help the holes to retain their circular shape. One of the most important things that you need to keep in mind is the orientation of the holes and they tend to be perfect when you print them along the xy-axis.

Text

Incorporating texts in the structures using the FDM technology can be quite a difficult thing to be especially if the thickness is not in the right range. If you are designing protruding text, then it is recommended to keep their thickness at 1mm. If you want the text to be legible then their height should be kept somewhere around 1.2-1.5mm. Always use large and regular fonts. The texts must remain parallel to the xy plane.

Gaps

If you are inserting thin gaps, then it should have a width of at least 5mm or more so that the support material from that space can be completely removed. The orientation of the gaps should also be kept in mind.

Tabs

If you are making tabs using the FDM technology then you should keep in mind that they are usually susceptible to breaking. So, one of the measures that you can take is to increase the size of the tab as much as you can. Moreover, their orientation in the xy-plane can also increase their strength and make them less prone to breaking. Another of the amazing ways in which you can prevent breakage of these tabs is by incorporating a replaceable tab design.

Fillets

If the idea is to replace the fragile features, then getting fillets can be one of the best options for you. They are one of the best features to enhance the structural rigidity and also eliminate the requirement of any separate support material.

Ribs

These are one of the best alternatives that you can use for fillets. When a certain amount of force is applied to a structure, ribs help in distributing that force evenly over the entire surface. The thickness of the ribs plays an important part because they should not be too thick or thin otherwise they can break.

The surface finish created by FDM structures is rough as compared to the other processes. If you are creating curved or shallow-angled surfaces, then this rough finish is even more visible. In order to reduce this, you can adjust the angles.

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