Minimum Wall Thickness:

• Aim for a minimum wall thickness of 1 mm for robust structural integrity.
• For high-stress applications, consider increasing this to 2-3 mm.

Minimum Detail Size:

• Ensure that the smallest feature size is at least 0.25 mm to maintain clarity.
• Complex textures or fine engravings should also respect this minimum limit.

Overhangs and Supports:

• Limit overhang angles to 35° or more to reduce the need for support structures.
• If supports are required, ensure that the design allows for easy removal without damaging the part.

Hollow Structures:

• Incorporate escape holes for powder removal if your design includes hollow or enclosed spaces.
• Holes should be at least 3-5 mm in diameter.

Clearance and Interlocking Parts:

• Leave a gap of at least 0.5 mm between interlocking parts to ensure smooth movement and prevent fusing.
• Larger assemblies may require a greater clearance based on part size and complexity.

Surface Quality and Finish:

• Be aware that unpolished titanium parts have a matte gray finish.
• If a smoother finish is desired, post-processing like polishing or bead blasting can help.

Design Complexity:

• Take advantage of 3D printing’s freedom to create complex shapes, such as lattice structures or organic forms.
• Consider topology optimization to reduce weight while maintaining strength.

Build Size Limits:

• Design within the build volume of the 3D printer, which typically ranges up to 250 x 250 x 250 mm.
• Larger designs may need to be printed in multiple parts and assembled afterward.

Heat Treatment and Stress Relief:

• Post-print heat treatment may be necessary to relieve stress and enhance material properties.
• Consider this during the design phase, especially for high-performance applications.