One of the most overlooked mistakes in metal 3D printing doesn’t happen during the print, it happens long before, during design. Engineers often push creative boundaries without fully considering one of the most rigid constraints: the size of the build chamber. Designing parts that exceed a printer’s build volume can turn a streamlined project into a segmented headache, requiring redesigns, extra support structures, or split-and-join strategies that add cost, complexity, and potential points of failure.
Oversized parts don’t just require rework, they disrupt the entire production workflow. Segmenting large components may introduce dimensional tolerances that are harder to control and increase the need for post-processing and inspection. In industries where precision is non-negotiable, such as aerospace or medical, this added uncertainty can translate into real-world performance risks.
Planning with the chamber in mind isn’t about limiting creativity, it’s about designing intelligently within the manufacturing reality. By understanding machine constraints from the start, engineers can design for manufacturability, reducing time-to-part and minimizing iterations. Smart design equals faster builds, less waste, and fewer surprises on the shop floor.
At Scojet, our design and DfAM teams work closely with clients to optimize geometries, segment only when necessary, and maximize the capabilities of each machine. Before you click “print,” make sure your part fits more than just the vision, it needs to fit the chamber.