Wall Thickness

In a generalized sense, a thickness of at least 1mm is usually advised for the walls. But if larger parts are involved then the wall thickness should be increased accordingly or reinforcements like fillets or ribs should be constructed. You can have walls of 0.5 mm in the case of hinges but in that case, the length has to be adjusted accordingly. It is usually considered to be 10mm when the hinges are attached at only one end and 25mm when the hinges are attached at both ends.

Holes

With this 3D printing technology, you will be able to create holes and perforations. A diameter of 2mm is usually recommended but you can also make holes of 1mm. But in case you are going for a complex structure then consider going for larger diameters only. A chain can be designed inside a complex duct that will aid in removing the residual powders stuck inside.

Hollowing

If the wall thickness of any model exceeds 20mm, you should consider hollowing it out as much as you can. This is important because it will prevent the formation of sink marks and will also save a lot of material. Thus, it will prove to be cost-effective for you. For aiding in powder removal, there must be a couple of holes present with diameters in the range of 2-3mm.

Interlocking Parts

With the MJF 3D printing technology, you can print interlocking parts even in a single build. But if you are designing parts that have to be printed together, you should keep in mind that a minimum clearance of 0.5mm has to be present.

Lattice Structures

These structures are a very clever way to reduce the material and weight of the structures. But there is a certain amount of gap that has to be maintained between the lattice beams in order to make them strong and stable. This gap is usually advised to be 1mm. The gap also allows you to remove the unfused lattice powder.

Engraved Details

For structures that are engraved on the surface, a thickness of about 0.25 mm should be maintained. But if you are engraving letters that have to be legible, the lines should have a minimum thickness of 0.5mm. Their height should be of 1mm at least. The overall height of the structures should be of 2.5mm.

Deformities

If you are designing flat plains or such related surfaces, you should not design them on something of the size of an A4 page. This will lead to the formation of deformities which are usually termed as warping. The problem will not be solved by the installation of the ribs. In fact, these reinforcements will increase the chances of deformation even more. Thus, flat planes should be avoided.

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