Designing for the Process

To achieve your objectives and optimize your results, it is important to know and consider the realistic capabilities and limitations of today's additive manufacturing processes and materials.  There are some inherent design constraints, as well as unique freedoms, that come with tool-less manufacturing that should be factored in for production of prototypes, models, patterns and tooling via layer additive processes.
 
For example, mating parts should not be modeled line-to-line or with overlapping interference.  Typically parts will not fit together without secondary post-processing that takes time and creates greater opportunity for error due to making manual modifications.  It is generally best to provide at least 0.010" clearance between mating surfaces to optimize fitment.  Likewise, it is important to design your 3d objects within the parameters of the process tolerances to achieve a satisfactory result.  Go to www.harvest-tech.com/quality for more details.
 
Small size constraints: