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Design Considerations for Rapid PrototypingBelow are some useful links that can serve as a guide to help you design your parts for rapid prototyping. There are only a few basic guide lines to follow to achieve the best possible part file that you can. If you have any question if your part will grow or not please ask your project manager and they will be able to answer any question you may have.
SLS The minimum feature size for SLS parts is typically .020”. Minimum recommended wall thickness is .030”. Part orientation can help certain features be produced more successfully. It is important to advise us if there are any critical dimensions that need to be achieved. DMLS Parts at built at such fine layers, fine features and tight tolerances are much more achievable with this technology. Certain geometries can meet tolerances as tight as .002” while others may only be achievable to .008”. The minimum wall thickness recommended can be as low as 0.010", but some walls need 0.020" Part orientation is also in significant in helping features and tolerances being met.
Stair stepping on parts built using DMLS is hardly visible but does exist. In general, surface quality of DMLS parts is very fine and requires very little post finishing. This occurs because the model is grown in layers. If the layers are further apart (.010") you will notice heavier stepping on your parts. If the layers are closer together (.006") then the stair stepping will be reduced and not be as noticeable. Another factor that effects the surface finish of the SLS model is Faceting. This is controlled by the output settings on your 3D CAD software. If you export a coarse setting the part will appear to have many triangles over the surface Coarse Image , however if you export a part with fine faceting the file may be to large and unmanageable Fine Image . The key is to fine the balance that will take into consideration features and part size to give you the best possible file.
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