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Design Guidelines for Engineers

General Modeling Guidelines
  • Export models in STL (standard) or 3MF (preferred for metadata like color/material).
  • Ensure watertight geometry — no holes, self-intersections, or non-manifold edges.
  • Design within the build volume: 256 × 256 × 256 mm.
  • Avoid floating parts or unsupported structures unless intentionally using supports.
    • Wall Thickness
  • Minimum wall thickness:
    ‍
    • 0.8 mm for PLA, PETG (2 perimeters with 0.4 mm nozzle).
    • Consider increasing to 1 mm for structural parts.
  • Top/Bottom layers: At least 3 layers (~0.6 mm at 0.2 mm layer height).
    • Holes and Tolerances
  • Holes often print undersized — add tolerance:
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    • Holes <5 mm: add +0.2–0.4 mm.
    • For pins/fits:
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      • Tight fit: 0.1–0.2 mm clearance
      • Sliding fit: 0.3–0.5 mm clearance
  • Avoid placing holes too close to edges — keep spacing ≥ hole diameter.
    • Assemblies and Mating Parts
  • Add clearances for snap-fits, interlocks, joints:
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    • PLA: 0.2–0.3 mm
    • PETG: 0.3–0.4 mm
  • Prefer heat-set inserts over printed threads.
  • Make sure touching components overlap by at least 0.01 mm to be merged in mesh export.
    • Overhangs and Bridging
  • Bambu A1 handles overhangs up to 45° without supports.
  • Beyond 45°, design support structures or chamfer transitions.
  • For bridges, keep span short (<10 mm) and support well on both ends.
    • Radii, Chamfers, and Edges
  • Add fillets or chamfers ≥ 0.5 mm to reduce stress concentration.
  • Always fillet internal corners, especially for load-bearing parts.
  • Avoid sharp corners that may cause layer delamination.
    • Orientation and Layer Strength
  • Orient parts to align stress along layer lines, not across.
  • Horizontal placement is better for strength and dimensional stability.
  • Flat bases ensure good adhesion; avoid printing on small contact points.
    • Hollowing and Infill
  • Use internal infill for strength-to-weight optimization; typical: 15–30%.
  • Avoid fully enclosed volumes — add vent holes to prevent trapped air and warping.
    • File Export Best Practices
  • Use STL or 3MF formats.
  • Set correct units (usually mm) and export tolerance: 0.01–0.1 mm for curves.
  • Check mesh quality using software like Netfabb, Meshmixer, Magics, or Bambu Studio.
    • File Export Best Practices
  • Use STL or 3MF formats.
  • Set correct units (usually mm) and export tolerance: 0.01–0.1 mm for curves.
  • Check mesh quality using software like Netfabb, Meshmixer, Magics, or Bambu Studio.

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