3D printing has revolutionized manufacturing, providing flexibility and innovation across industries. However, it’s no secret that costs can quickly add up, whether you're creating prototypes or end-use parts in your 3D print shop. The good news? With the right strategies, you can significantly reduce the cost of printing 3D objects without compromising on quality.
This article explores practical tips and best practices to help businesses and hobbyists achieve affordable 3D printing. From optimizing designs to leveraging community resources, read on to learn how to get the most value out of your 3D printing efforts.
Optimizing the design of your parts is an important part of achieving cost-efficiency in 3D printing. By applying Design for Additive Manufacturing (DFAM) principles—such as minimizing material use, refining geometries, and adopting structural efficiencies—you can unlock significant savings while improving part performance.
Design Parts with Minimal Volume and Bulk
Reducing unnecessary bulk and volume in your design can lead to cost savings, faster production, and improved part efficiency. By focusing on material optimization, you can streamline designs without sacrificing performance.
By refining your design for volume efficiency, you can achieve faster, more economical 3D printing while maintaining strength, functionality, and performance.
Reduce Z-Height to Improve Efficiency
Decreasing the Z-height (vertical dimension) of your design can often lead to faster print times and lower material usage, particularly in FDM and SLA/DLP printing, where layers are built sequentially. However, in powder-bed technologies like SLS, SAF, and MJF, reducing Z-height does not necessarily decrease material consumption, as the entire build volume is utilized regardless of part height. Instead, optimizing part orientation and nesting within the build space can yield better efficiency in these processes.
Additionally, part orientation significantly impacts material usage due to support structures. In processes like FDM, SLA, and PolyJet, parts printed at an angle or with overhangs require additional supports, increasing waste, material costs, and post-processing time. Choosing a self-supporting orientation—one that minimizes overhangs—can reduce unnecessary material consumption and improve surface finish.
Optimize Internal Structures for Material Savings
Incorporating hollow structures can reduce material usage and weight without sacrificing strength, but printability and post-processing constraints must be considered.
For powder-based (SLS, SAF, MJF) and resin-based (SLA/DLP) printing, enclosed cavities can trap unused material, making removal difficult or even impossible. To prevent this:
For FDM, SLA, and PolyJet, using self-supporting internal structures—such as lattice or ribbed designs—can reduce material usage while maintaining strength. In these technologies, completely hollow sections may collapse or print poorly without internal reinforcement.
Ultimately, the best strategy depends on your chosen 3D printing process, functional requirements, and post-processing needs.
Stratasys Direct has helped hundreds of companies optimize their projects with these cost-saving strategies to save them money and lead time, without sacrificing functionality. We offer advanced 3D printing solutions and cutting-edge technology and expertise that ensures high-quality, cost-effective results.
Your choice of printing technology has a direct effect on your 3D printing costs. By selecting the most cost-effective printing process, you can optimize production and minimize expenses.
Become Familiar with your AM Options
Understanding the pros and cons of different technologies is essential for making informed decisions. Each printing technology has its own advantages and limitations. For instance, Fused Deposition Modeling is typically more affordable for basic prototypes, while powder bed fusion may be better for complex geometries and lightweighting parts.
Consider the Application
Before you begin your project consider your requirements for the application: Will this be a functional part? Is this a concept model that needs to hyper-realistic and in color? Does the part need to be durable or last for a period of time? How many components do you need to make? Answers to questions like these can help narrow down which technology you ultimately choose.
By carefully selecting the right printing technology, you can make informed decisions that best fit your project. RapidQuotes™ makes it easy to upload designs, receive instant pricing, and move forward quickly. For larger, more complex projects—or if additional guidance is needed—our experienced team is available to provide insights on materials, technologies, and optimization strategies.
Choose Economical Materials
Material selection is one of the biggest factors that influences your 3D printing cost.
Opt for materials that deliver the properties you need at a manageable price point. With more than 50 engineering grade materials in our portfolio, we understand how challenging that decision can be. That’s why Stratasys Direct offers a “Help Me Choose” feature in RapidQuotes™, our online quoting platform. This useful feature enables you to review material options, filter through their characteristics and properties to find the material that best fits your needs and budget. By comparing prices, you can identify cost-effective options that still meet your requirements without breaking the bank.
Support structures and post-processing play a role in many 3D printing processes, impacting cost and production time. While post-processing enhances appearance, functionality, and performance, reducing unnecessary supports and optimizing print settings can improve efficiency without compromising quality.
Leverage Self-Supporting Design Where Possible
In processes that require support structures, designing self-supporting geometries can help minimize material use and post-processing time. Strategic part orientation can also improve surface quality and reduce reliance on supports, streamlining the finishing process.
Balance Layer Height and Resolution for Efficiency
Layer height impacts build speed, surface finish, and post-processing needs. While thicker layers can speed up production, they may require additional finishing depending on design requirements. In contrast, higher-resolution printing can produce smoother surfaces upfront, potentially reducing sanding or polishing steps. Selecting the right balance helps optimize both quality and efficiency.
For companies looking to scale production without investing in additional equipment, outsourcing 3D printing services to a trusted provider like Stratasys Direct can be a strategic advantage. This approach allows businesses to leverage high-quality additive manufacturing without the need for in-house capital investment, equipment maintenance, or production overhead.
Flexible Solutions—Whether You Own a Printer or Not
Many companies begin with outsourced 3D printing services before investing in their own equipment, while others with in-house printers continue to use external services to expand capacity, access specialized materials, or leverage advanced expertise. Even businesses with additive manufacturing experience may find outsourcing beneficial for scaling production, tackling complex projects, or reducing lead times.
Partner with a Proven Industry Leader
With 30+ years of experience, Stratasys Direct provides industry-leading manufacturing expertise, tight tolerances, and large-scale production capabilities. Our deep knowledge of material selection, process optimization, and finishing techniques ensures high-quality results while maintaining cost efficiency.
By outsourcing to an experienced service provider, businesses can scale production, streamline operations, and accelerate time-to-market while maintaining flexibility in their manufacturing strategy—whether they’re new to additive or already invested in 3D printing technology.
With nearly two decades in the 3D printing industry, Eric has played a pivotal role in both the hardware and services sides of Stratasys. His deep expertise in FDM and PolyJet technologies has taken him from engineering and product management to his current leadership in digital marketing, where he drives SEO, content strategy, paid advertising, and web development for Stratasys Direct. Beyond marketing, Eric has extensive hands-on experience in additive manufacturing, from optimizing 3D printing processes to designing functional prototypes, sales samples, and custom parts for both industrial and personal applications.
