Remember 45 degree rule, overhangs that are greater than 45 degrees will need support material or you need to use clever modeling tricks to get the model to print. Create your own support / bridging objects (cones and other supports) by designing them into your model.
Design To Avoid Using Support Material
Although support algorithms are improving all the time, support material can leave ugly marks on the outside of your prints. Support material can also be time consuming to remove. Design your models so that they are 3D printable with minimal support.
Add Custom Supports
Use “mouse ears”, helper disks and cones designed into your model to help it print without the use of computer generated supports. Tony Buser’s “Mouse Eared Rocket Fincan” and PrettySmallThings “Windsor Chairs” are excellent example of this design technique.
Know 3D Printing Limitations in Egypt
Know your model details. Are there tiny towers and small features that are too small to be printed in plastic on a desktop 3D printer? An important, but often overlooked, variable in what 3D printing in Egypt can achieve is thread width.
Thread width is determined by the diameter of printer’s nozzle. Most printers have a 0.4mm or 0.5mm nozzle. Practically, this means that a circle drawn by a 3D printer is always two thread widths deep: 0.8mm thick with a 0.4mm nozzle to 1mm thick for a 0.5mm nozzle. Etba3ly 3D's Only Advice in this matter is that “The smallest feature you can create is double the thread width.”
Fit Tolerances for Interlocking Parts
For objects with multiple interlocking parts, design in your fit tolerance. Getting tolerances correct can be difficult. Use a 0.2mm offset for tight fit (press fit parts, connecters) and use a 0.4mm offset for lose fit (hinges, box lids). You will have to test it yourself with your particular model to determine what is the right tolerance for the thing you are creating.
Use Shells Properly
Don’t use additional shells on fine featured models, like small text. It will obscure the detail.
Optimize for Thread Width
Use thread width to your advantage. If you are making flexible models or need very thin features, design the walls of your model to be one thread width thick. Check out Hultgren’s collection of “Flexible Inspiration” model collection on Thingiverse for more examples on utilizing this technique.
The “Holy Grail”: Print and Place Designs
Print in place designs that contain multiple integrated parts, are the “Holy Grail” of FDM 3D printing at Etba3ly 3D in Egypt.