In metal 3D printing, part orientation is not just a setup detail, it’s a critical factor that can make or break your build. One of the most overlooked risks? Unsupported overhangs. These features, especially when exceeding 45°, are highly prone to defects such as sagging, distortion, or poor layer adhesion. That’s because molten metal can’t bridge long horizontal spans without gravity pulling it out of shape.
The solution isn’t just to slap on supports everywhere. Proper orientation planning means strategically rotating the part to reduce or eliminate unsupported areas, especially on downward-facing surfaces. If certain overhangs are unavoidable, they should be reinforced with purpose-built support structures or redesigned to be self-supporting using gradual angles or ribs.
Additionally, keeping your angles under control plays a huge role in print consistency. Even minor orientation adjustments can drastically reduce the amount of support material needed, lower residual stress in the part, and minimize the need for post-processing. That means smoother surfaces, tighter tolerances, and faster turnaround times.
Remember: print quality doesn’t begin at layer one, it begins the moment you set the build orientation. Get that wrong, and no amount of post-processing will fully recover a compromised part.