5 Proven Ways to Slash 3D Printing Costs

3D printers produce parts on a layer-by-layer basis, fusing or bonding one cross-section at a time until the whole object is formed. For powder bed fusion processes, such as SLS, HP Multi Jet Fusion, and DMLS, the machines melt layers of powder and then moves incrementally up to create the next level. For extruding/jetting processes, the material is ejected through a printhead nozzle. SLA and DLS processes balance layers and cure times. For every layer, which varies from 0.001”–0.013” in height depending on the process, there is a mechanical movement that can add a lot of time to a part’s build. Pairing the vertical movement, recoating of material layers, and even incremental automated printhead cleaning can add hours of machine time.

Minimizing the vertical Z-height of the part is a great way to keep printing costs down. Sometimes splitting parts is also more economical than increasing height. With a lower part height, the impact of the machine activity between layers is mitigated and the costs are focused more on direct material costs.

Xometry’s SLS, HP Multi Jet Fusion, FDM, SLA, DLS, PolyJet, and DMLS processes all use printers with various maximum build platform sizes. These are integrated into our AI-based quoting algorithms, which means that parts that can be built lying on their side (horizontally) tend to be more cost-effective than those that have to be built with their longest face in the vertical direction.

Here are some good “best practices’ lengths to keep in mind when designing your part for a particular process. Staying under these will generally ensure a lower-priced part. Another way to think about it is that if you stay under half the available platform size then you can get multiple parts on the build, allowing some overhead costs to be shared.