Tolerance Cost Curve: Why Tight Specs Drive Post-Processing In additive manufacturing, tighter tolerances do not come for free, they come with increased complexity, time, and cost. Each increment of precision typically requires additional post-processing steps... May 5, 2026 Post-Processing & Reliability
Heat Exchanger Core: Printed Prototype to Cast Production Heat exchangers are among the most complex components in modern engineering, requiring precise control of internal geometry to optimize fluid flow and thermal performance. Traditional manufacturing me... May 5, 2026 Industrial Applications & Use Cases
Large Flat Panels Without Ribs or Relief Large flat surfaces are one of the most challenging geometries in metal additive manufacturing. While they may appear simple in CAD, they are highly susceptible to warping, distortion, and internal st... May 5, 2026 Design for Additive Manufacturing
Use Standard Hardware (Pins/Inserts) to Simplify Design One of the most common mistakes in additive design is trying to print every feature directly into the part, including threads, alignment pins, or wear surfaces. While this may seem efficient, it often... Apr 28, 2026 Design for Additive Manufacturing
Material Selection Cheat-Sheet for Common Alloys Material selection is one of the most critical decisions in additive manufacturing, often determining the success or failure of a part before it is even printed. Each alloy brings its own balance of s... Apr 28, 2026
Myth: AM Parts Can’t Hit Tight Tolerances A common misconception in additive manufacturing is that it cannot achieve the tight tolerances required for high-performance applications. While it’s true that as-printed parts may not match CNC-leve... Apr 28, 2026 Repeatability and Process Control
Prototype-to-Production Handoff: What Changes Transitioning a part from prototype to full-scale production is one of the most critical, and often underestimated, phases in product development. What works in a prototype environment does not automa... Apr 21, 2026 Repeatability and Process Control
Myth: One Part Orientation Works for Every Build A common misconception in metal additive manufacturing is that a single build orientation can be applied universally across different parts. In reality, orientation is one of the most critical variabl... Apr 21, 2026 Additive Manufacturing Fundamentals
Lighting Prototype: Printed Housing That Guides Die-Cast Design In product development, one of the biggest bottlenecks is waiting for production tooling before validating a design. This is especially true in applications like LED housings, where thermal performanc... Apr 21, 2026 Industrial Applications & Use Cases
Over-Designing Threads Instead of Using Inserts Designing threads directly into 3D-printed parts may seem like a convenient solution, but it often leads to weak and unreliable connections. Additive processes struggle to produce high-quality interna... Apr 14, 2026 Design for Additive Manufacturing
Surface Finish Options: As-Printed, Machined, or Surface Treated Surface finish plays a critical role in both the performance and appearance of metal additive manufactured parts. While as-printed surfaces can be sufficient for certain applications, they typically e... Apr 14, 2026 Post-Processing & Reliability
Combine Small Brackets into One Printed Assembly One of the most impactful advantages of additive manufacturing is the ability to consolidate multiple components into a single, optimized structure. Traditional assemblies often rely on several small ... Apr 14, 2026 Advanced Structures & Lightweighting