In metal additive manufacturing, the choice of layer thickness plays a pivotal role in balancing productivity, resolution, and material integrity. While it might seem like a minor parameter, it directly impacts the quality, efficiency, and downstream processability of the printed part. Thicker layers (e.g., 60–90 µm) speed up build times significantly but often reduce detail resolution and may introduce surface roughness. In contrast, thinner layers (e.g., 20–40 µm) offer finer detail and better surface finish but extend build durations and increase residual stress.
The trade-off isn’t always straightforward. Functional parts with complex geometries, sharp details, or tight tolerances benefit from thinner layers, especially in tooling inserts or medical implants where precision is critical. On the other hand, larger industrial parts, like brackets or frames, can often be printed with thicker layers without compromising function, accelerating production and lowering costs.
It’s also important to consider the material used. For instance, titanium alloys can tolerate thicker layers with reasonable detail, while stainless steels may require thinner layers to avoid edge distortion. Regardless of material, the choice must reflect both the part’s purpose and the post-processing steps that follow (e.g., CNC, polishing).
Ultimately, optimal layer thickness is not about always choosing thinner or faster, it’s about aligning print strategy with functional requirements. Simulation tools and empirical data help identify the sweet spot for each use case.
Smart additive design starts with understanding your layers. Every micron counts.