additivetools
All tools

DfAM Design Rules Checklist

Universal

The minimum-feature rules every AM service bureau quotes — collected from manufacturer guides and ISO/ASTM 52910. Type your design value into any rule to see whether it falls in the aggressive, typical, or conservative window for your chosen process.

Process

Limits driven by powder size (15–45 µm), laser spot, and thermal stress. Steel and Ni alloys hit closer to the aggressive end; Ti6Al4V and AlSi10Mg need typical-or-conservative for first builds.

Walls

  • Minimum wall thickness

    ≥ per row

    Below typical, walls warp from residual stress and may not consolidate fully.

    Source: EOS / GE Additive design guides; ISO/ASTM 52910

    Aggressive0.300 mm
    Typical0.500 mm
    Conservative0.800 mm
    mm

Holes

  • Minimum vertical hole diameter

    ≥ per row

    Vertical (build-axis) holes hold tolerance well; aggressive values need post-machining.

    Aggressive0.500 mm
    Typical1.00 mm
    Conservative1.50 mm
    mm

  • Minimum horizontal hole diameter

    ≥ per row

    Horizontal holes sag at the top — round becomes teardrop. Diamond/tear shape compensates.

    Aggressive1.00 mm
    Typical2.00 mm
    Conservative4.00 mm
    mm

Overhangs

  • Self-supporting angle from horizontal

    ≥ per row

    Surfaces below this angle need supports. Steeper = freer of supports.

    Source: Renishaw, EOS guides

    Aggressive30.0 °
    Typical45.0 °
    Conservative60.0 °
    °

  • Max unsupported overhang length

    ≤ per row

    A horizontal lip beyond this without supports will droop or cause recoater hits.

    Aggressive1.00 mm
    Typical0.500 mm
    Conservative0.200 mm
    mm

Channels

  • Minimum internal channel diameter

    ≥ per row

    Smaller channels can't be powder-cleaned reliably and may close from sintered fines.

    Aggressive0.500 mm
    Typical1.00 mm
    Conservative2.00 mm
    mm

Features

  • Minimum embossed text height

    ≥ per row

    Below this, edges blur and characters become illegible after powder removal.

    Aggressive0.300 mm
    Typical0.500 mm
    Conservative1.00 mm
    mm

Build prep

  • Minimum spacing between parts on plate

    ≥ per row

    Tighter packing risks heat coupling and stress accumulation between parts.

    Aggressive1.00 mm
    Typical3.00 mm
    Conservative5.00 mm
    mm

How to read these values

  • Aggressive — push the envelope. Only safe if you fully control machine, parameters, and material.
  • Typical — what most service bureaus quote and what shows up in default machine recipes.
  • Conservative — works on entry-level hardware, junior operator, first build. Always safe.

Sources

Related tools