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The DfAM pre-print checklist
Run this before every print that matters — the same sequence we use in design reviews. Thirty checks, in the order the decisions get made.
1. Process fit
- Material requirements (temp, chemical, cert) are written down and the process can print them
- The process was chosen with reasons, not habit
- Quantity justifies additive (molding/machining crossover checked)
- Part fits the build volume with orientation freedom
- Unit cost includes post-processing labor, not just machine time
2. Geometry
- Walls are integer multiples of extrusion width / above process minimums
- Every downward surface is > 45° from vertical, bridged, or chamfered
- Side holes over ~10 mm are teardropped
- Mass is in ribs and box sections, not solid thickness
- No trapped volumes; powder/resin escape holes ≥ 3–5 mm
- Sharp internal corners are filleted
3. Orientation & strength
- Primary load runs in-plane (XY), not across layers (Z)
- Orientation chosen for strength and critical surfaces first, supports second
- Cosmetic faces don't sit on supports
- Anisotropy accounted for (Z at 40–80% of XY until tested)
- Snap-fits and compliant features flex in-plane, with root fillets
4. Materials in service
- Service temperature is below the material's HDT with margin
- Creep under sustained load is considered
- UV, moisture, and chemical exposure match the material
- Fasteners use inserts or through-bolts, not bare printed threads under M6
- The exact filament/resin/powder SKU is recorded
5. Release evidence
- The 3–5 dimensions that matter carry process-capable tolerances
- Every functional hole has a compensation or post-drill plan
- An inspection method exists for each toleranced feature
- Strength-affecting print settings are captured in the drawing/record
- A test coupon or first-article plan exists for the real load case
- Someone other than the designer can print this from the package alone
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