3D Print Optimization: How Smarter Design Saves Time and Money

3D printing is a powerful technology for creating both prototypes and finished products, but poorly optimized designs can lead to unnecessary costs and extended print times.
By following a few simple design principles, you can reduce material usage, minimize support structures, and streamline your printing process. In this guide, you’ll find practical tips to design smarter and save both time and money on your 3D prints.

1. Design with the printing process in mind

Different 3D printing technologies have different strengths and limitations. When designing, consider:

• FDM: Avoid excessive overhangs and complex geometries that require support. Best for functional parts with moderate detail

• SLA: Ideal for detailed, smooth surfaces but typically requires post-processing. Great for jewelry, dental models, and miniatures

• SLS: Requires no supports but is more expensive. Excellent for functional prototypes and strong components
  Choosing the right technology for your design and application helps reduce the need for redesign later in the process.

2. Reduce the need for support structures

Supports increase print time and material use. To minimize them:

• Optimize part orientation in the slicer to reduce overhangs

• Design self-supporting angles, ideally under 45 degrees

• Use bridges to span gaps without support

• Split models into multiple parts that can be printed without support and assembled afterward
  Minimizing support not only saves material, but also reduces post-processing time.

3. Optimize wall thickness and infill

Use only as much material as needed to ensure structural integrity:

• Infill percentage: 20–30% is typically enough for functional prototypes, while more demanding applications may require 50%+

• Wall thickness: Thinner walls reduce material use but must be strong enough. A thickness of 1.2–2.4 mm is generally ideal

• Lightweight structures: Use honeycomb or grid patterns to reduce weight and material without sacrificing strength

4. Use effective layer heights

Layer height affects both quality and print speed:

• Low layer height (0.1 mm) provides high detail but increases print time

• High layer height (0.3 mm) prints faster with less detail—great for functional parts without fine features
  Find a balance depending on your needs. For visual prototypes, a mid-range setting often provides the best trade-off.

5. Choose the right material

Material selection directly affects cost and performance:

• PLA: Cheap, easy to print, but not very durable—ideal for non-functional models

• PETG: More flexible and stronger than PLA, with good chemical and moisture resistance

• ABS: Heat-resistant but requires a heated bed and emits fumes

• PA6 (Nylon): Very strong and wear-resistant but needs high precision and heat

• TPU: Flexible material used for gaskets, soft components, and impact-absorbing parts
  Choosing the right material from the start can reduce failed prints and costly iterations.

6. Test before printing full-scale

To avoid expensive mistakes:

• Print a miniature version to test form and fit

• Print critical sections before committing to the full model

• Use slicer preview tools to identify problem areas

• Test in cheaper materials like PLA before printing in expensive options like Nylon or resin
  Small test prints can prevent large-scale failures and save money.

7. Use post-processing instead of ultra-high detail

Rather than printing at ultra-fine resolutions, consider using finishing techniques:

• Sanding and polishing to smooth visible layers (especially with PLA and ABS)

• Chemical smoothing (e.g., acetone for ABS) to eliminate layer lines and create a glossy finish

• Painting and coating to improve visual appearance without ultra-fine printing

• Bonding and assembling parts rather than printing large objects as a single piece
  Post-processing can give your prints a professional look and save time during printing.

8. Software optimization and troubleshooting

Use the right tools to fine-tune your designs and prevent errors:

• Slicer software like Cura, PrusaSlicer, or Simplify3D helps spot and fix issues before printing

• Mesh repair tools like Meshmixer or Netfabb can correct STL errors

• Temperature tuning ensures optimal extrusion and adhesion

• Support settings can be customized to reduce material use
  Good software settings can improve print quality just as much as hardware adjustments.

Conclusion

By optimizing your 3D designs, you can reduce print time, lower material costs, and improve the quality of your prints. Always consider the printing technology, support requirements, infill, wall thickness, and material selection to get the best results. Smart design decisions and well-tuned print settings save both time and money—without compromising on quality.

Need help optimizing your 3D designs? Contact Maker Factory today—we’re here to help you get more from every print!