How to Optimize Your SolidWorks Models for 3D Printing

Introduction

3D printing has revolutionized the way engineers and designers bring concepts to life. However, creating a SolidWorks model that prints flawlessly requires more than just hitting "Export to STL." In this post, we'll explore essential tips and best practices to ensure your designs are optimized for 3D printing—saving you time, material, and frustration.

1. SolidWorks File Export Formats

While STL is the most common format for 3D printing, STEP and 3MF files can sometimes offer better compatibility and higher accuracy. Ensure you’re using the right format for your printer and slicing software.

💡 Tip: When exporting an STL, set the resolution to "Fine" or manually adjust the chordal tolerance to maintain surface smoothness.

2. Ensure Model Watertightness

For a successful print, your SolidWorks model must be watertight, meaning it has no open edges or gaps. Use the “Check” tool or SolidWorks Inspection to identify potential issues.

🔧 Fix: If your model is not solid, try using the “Combine” or “Knit Surface” feature to merge separate surfaces into a single solid body.

3. Optimize Wall Thickness

3D printers require a minimum wall thickness to produce a structurally sound object.

• For FDM printing, aim for at least 1.2 mm wall thickness.

• For SLA/DLP printing, 0.6 mm may be sufficient, but thinner walls can be fragile.

📏 Use SolidWorks Thickness Analysis to detect thin areas before exporting.

4. Minimize Overhangs & Add Supports if Necessary

Overhangs greater than 45 degrees may require support structures, which increase material usage and post-processing work.

🔍 Solution: Use the “Draft” tool in SolidWorks to angle overhanging surfaces and reduce the need for supports.

5. Check for Small Features & Tolerances

Printers have physical limitations in detail reproduction. If your model has fine details or moving parts, check your printer’s resolution to ensure everything prints correctly.

🎯 Tip: Increase feature size or use embossed instead of engraved text for better readability.

6. Optimize Infill & Internal Structures

If your model is solid, it may use unnecessary material and take longer to print. Instead:

✅ Use “Shell” or “Hollow” Features to reduce weight✅ Adjust infill percentage in your slicer to balance strength and material usage

Conclusion

By following these SolidWorks optimization tips, you can create 3D-print-ready models that are accurate, efficient, and require minimal post-processing. Whether you’re printing prototypes or functional parts, these techniques will ensure smooth and successful results every time!

🚀 Have you faced challenges optimizing SolidWorks models for 3D printing? Share your experience in the comments!