Designing for large-scale 3D printing applications

In large-scale, robotic 3D printing, quality does not start at the machine. It starts at the design stage. When engineers take into account how an object will actually be built layer by layer, the result is not only improved manufacturability, but also greater efficiency and predictability throughout the project.

A design that aligns with the printing process reduces interruptions, increases structural stability and improves overall consistency. In practice, three design guidelines are particularly influential.

1. A continuous toolpath per layer

Wherever possible, it is beneficial to design each layer so it can be printed in one continuous movement.

This approach leads to:

  • More uniform material deposition

  • A cleaner and more consistent surface finish

  • Fewer weak spots caused by stops or restarts

Every interruption in the print process can affect layer bonding. By designing geometries that enable a continuous toolpath, we reduce potential failure points and improve structural reliability.

2. Managing overhangs intelligently

Layer adhesion is critical in large-scale printing. Each new layer must be sufficiently supported by the previous one.

A practical rule of thumb is to ensure adequate overlap between layers. Steep inclines increase the risk of sagging or deformation during printing.

This is why we design:

  • Gradual transitions instead of abrupt changes

  • Integrated supporting forms

  • Inclination angles that match the material behaviour

By incorporating these principles early on, the structure remains stable during production and the likelihood of rework is reduced.

3. Deliberate seam placement

In more complex geometries, such as infill structures, patterns or functional details, seam lines are often unavoidable.

The key question is not whether they appear, but where. By intentionally positioning seam lines, they can be:

  • Visually integrated

  • Structurally controlled

  • Used as a deliberate design feature

This transforms seams from incidental artefacts into managed design elements.

Designing for robustness

Beyond these three guidelines, it is beneficial to keep designs simple, robust and tolerant.

This includes:

  • Consistent wall thicknesses

  • Smooth geometries

  • Avoiding unnecessary detail

These choices reduce process sensitivity and contribute to a more reliable production flow.

By embedding these principles at the design stage, we move towards higher print quality, shorter production times and a smoother path to realisation. In large-scale 3D printing, design and manufacturing are not separate phases, but part of one integrated process.