What's the best way to 3D print complex shapes?

1 Choose the right design software

The first step to 3D print complex shapes is to use a design software that suits your needs and skills. There are many options available, from free and open-source programs like Blender or Tinkercad, to professional and paid ones like SolidWorks or Fusion 360. Depending on your project, you may want to use a software that has features like sculpting, parametric modeling, mesh editing, or simulation. You should also consider the file format, compatibility, and export options of your software, as they may affect the quality and accuracy of your 3D print.

2 Optimize your model for 3D printing

Once you have your design ready, you need to optimize it for 3D printing. This means checking and fixing any issues that may cause printing problems, such as non-manifold geometry, holes, gaps, or inverted normals. You can use tools like Meshmixer or Netfabb to analyze and repair your model, or use online services like MakePrintable or 3D Builder. You should also reduce the polygon count of your model, as too many faces can slow down the slicing process and increase the file size.

3 Select the best printing settings

The next step is to select the best printing settings for your complex shape. This includes choosing the right material, nozzle size, layer height, infill, temperature, speed, and cooling. Depending on your shape, you may want to use a material that has good strength, flexibility, or detail, such as PLA, ABS, or resin. You may also want to use a smaller nozzle size and layer height for finer details, or a larger one for faster printing. You should also adjust the infill, temperature, speed, and cooling to avoid warping, cracking, or stringing.

4 Use supports and rafts wisely

One of the biggest challenges of 3D printing complex shapes is dealing with overhangs and bridges. These are parts of your model that are not supported by the previous layer or the build plate, and may sag or collapse during printing. To prevent this, you need to use supports and rafts. Supports are additional structures that hold up the overhanging parts of your model, and rafts are thin layers that provide a stable base for your print. However, supports and rafts can also cause problems, such as wasting material, increasing print time, or leaving marks on your print. Therefore, you should use them wisely and only when necessary. You can use your slicing software to customize the placement, density, and type of supports and rafts, or use advanced techniques like tree supports, soluble supports, or adaptive layers.

5 Experiment with different orientations and positions

Another way to improve your 3D printing results is to experiment with different orientations and positions of your model on the build plate. By changing the angle or direction of your model, you can reduce the amount of supports needed, increase the strength or detail of your print, or avoid printing errors. For example, you can rotate your model to align the longest axis with the Z-axis, which will reduce the number of layers and print time. You can also position your model to avoid overhangs on the front or back sides, which will improve the visibility and aesthetics of your print. You can use your slicing software to preview and adjust the orientation and position of your model, or use online tools like 3D Print Toolbox or 3D Rotation Tool.

6 Post-process your print for a smooth finish

The final step to 3D print complex shapes is to post-process your print for a smooth finish. This means removing any supports, rafts, or excess material from your print, and applying some methods to enhance the appearance and quality of your print. Depending on your material and shape, you can use techniques like sanding, trimming, filing, or scraping to smooth out the surface of your print. You can also use methods like acetone vapor smoothing, epoxy coating, or UV curing to create a glossy or transparent effect on your print. You can also paint, dye, or polish your print to add some color or shine to your print.

7 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?