In metal additive manufacturing, one overlooked design mistake can lead to costly print failures: forgetting to account for recoater clearance. The recoater blade spreads each new layer of powder, and if a tall part sits too close to the build plate edge, it can collide with the blade during operation.
This type of contact can result in layer shift, build crashes, or complete print failure. To avoid this, designers should always leave a minimum horizontal clearance between the recoater’s path and the part geometry, typically between 2 and 5 mm.
If clearance isn’t feasible due to part layout, other options include adjusting the build orientation, lowering the part’s height, or adding temporary support features to stabilize the geometry. Another smart move? Simulate the recoater path in your build software before committing to the job.
Avoid surprises on the build plate. Respect the recoater’s path, it’s essential for reliable, repeatable printing.