Our 3D printing process, from A to Z

Overview

From model to part in four steps

Filawerk is a contract printing service: you bring the file, we bring the machines, the material and the experience. You need neither a printer of your own nor prior knowledge and the configurator guides you through every decision and suggests a sensible default at each step.

The whole process runs in four steps, each explained in detail on this page. If you're in a hurry: upload your file, accept the recommendation everywhere and order, that works perfectly for the vast majority of parts. If you want to get the most out of it, it's worth reading the chapters on material, quality and design guidelines.

1. 1
   Upload model
   You upload your 3D file. We check it automatically for printability and show you a preview.
2. 2
   Material & color
   You pick the material and color. We start with sensible default settings that you're free to adjust.
3. 3
   Set the quality
   You set the layer height and infill.
4. 4
   Order
   You add the part to the cart and pay. We print, check and ship.

1Model

Prepare & upload your model

It all starts with your 3D file. A 3D file describes the shape of your object as geometry, essentially the blueprint from which our printers build the real part layer by layer. You get such files from any common 3D program, download them from an online database, or receive them from a design studio.

Which file formats we accept

We accept the three most common formats. When in doubt, STL is the safest choice, since almost every program can export it.

The maximum file size is 50 MB per model. That's enough for almost any single part. If your file is larger, it's usually due to unnecessarily high resolution. Re-export it with a slightly lower resolution, or send it to us via email and we'll take a look at it for you.

Check unit & size

The most common mistake on a first print is the wrong size. STL files carry no unit, so we interpret the numbers as millimeters. If your model was designed in centimeters, meters or inches in some program, it can suddenly become ten or more times too small or too large. In the configurator you see the real dimensions in millimeters and can scale them with one click.

What happens automatically on upload

Behind the scenes your file runs through exactly the process we also use to print, so we see right away whether it works:

1. 1
   Conversion to STL
   Whatever format you upload, we first convert it into an STL. If that runs through cleanly, it's already confirmed that it's a valid, closed 3D geometry and not a broken file.
2. 2
   Slicing with OrcaSlicer
   We hand the STL to the OrcaSlicer engine, the same software that later generates the print paths. It automatically orients your part optimally and adds supports automatically where needed.

In doing so the slicer checks the same things that matter for the real print:

• Valid geometry: Whether the mesh can be sliced into clean layers at all, i.e. contains no broken or non-manifold spots.
• Fits the print bed: Whether your part fits our build volume. If it's too large, the configurator shows you an error right away and you can scale it down or upload a smaller model.
• Automatic orientation: The most print-friendly position on the bed, for a better surface and fewer supports.
• Automatic supports: Overhanging sections are detected and automatically supported during slicing.

We repair minor errors automatically on request. For bigger ones we contact you personally before we print. You'll should never receive a faulty part.

2.1Material

Choosing the right material

The material determines how your part feels in the end and what it can take. We deliberately offer three different plastics that cover the typical applications for home use and hobby or functional parts well. For highly specialized industrial applications there are far more exotic materials, those aren't in our range at the moment. All our filaments come from brand-name manufacturers like Prusament and Polymaker, no anonymous cheap stock.

The short version

Which material when?

A simple rule of thumb: if your part only needs to look good, take PLA. For general mechanical parts, take PETG. For very demanding applications, take PC. If it needs to bend, take TPU.

2.2Color

Color & finish

We keep over 30 colors in stock permanently. From bold red, brilliant gold, classic black or pastel. Which colors are available depends somewhat on the material: PLA comes in the full selection, PETG in a steadily growing and PC & TPU in a smaller palette.

How the color is made

In 3D printing the color isn't painted on, it's in the plastic itself. So the part is colored all the way through and can't flake off. Each color is its own spool of material that we load into the printer before your print. A single part therefore has exactly one color, for multi-color objects the components have to be printed separately. Alternatively, we can use a multi-color technique on request via e-mail.

Finish & gloss

Standard filaments have a slight silk sheen. Many of our filaments are matte grades for a more refined, less reflective look. You can influence the visible print layers via the layer height, more on that in the next chapter. If you need a completely smooth surface, post-processing (sanding, priming, painting) is required.

3Quality

Layer height & infill

Here you decide the compromise between detail, strength, print time and price. Two settings are central: the layer height (how fine the individual layers are) and the infill (how solid the part is inside).

Layer height

Our printers build your part from many thin layers. The thinner each layer, the smoother the surface and the finer the details, but the longer the print takes and the more it costs. We offer three levels:

Infill

3D-printed parts are rarely completely solid inside. Instead a honeycomb-like lattice (we use gyroid infill) fills the interior. That saves material, weight and time without changing how the part looks outside. You give the infill as a percentage:

• 10–15% is light and cheap. For decor and parts that bear no load.
• 20–35% is the standard. Strong enough for the vast majority of uses.
• 40–65% is much more load-bearing. For parts that must withstand real forces.
• 70–100% is nearly solid. Only when maximum strength matters. Expensive and heavy.

Support structures

Parts with far-projecting sections need a temporary support during printing so nothing is printed into thin air. We remove these supports by hand after the print and finish the affected spots. You don't have to worry about it, we detect automatically where they're needed and factor them into the price.

4Order

How your price is calculated

Our price is not an estimate and not a quote you have to wait for, you see it instantly and to the cent before you order. It consists of five transparent components, with no hidden fees.

Volume discount

If you need several identical parts, it gets cheaper per piece because the preparation is spread across more parts. When you increase the quantity the setup costs are reduced accordingly.

Best Practice

Design guidelines for good prints

If you design your model yourself, a few simple rules decide whether the result comes out clean and strong. These guidelines apply to all three materials; larger dimensions tend to be less critical than very small ones.

Minimum dimensions at a glance

Overhangs & bridges

Surfaces that deviate more than about 45° from vertical need support material. Where possible, it pays to orient or design a part so such overhangs are avoided. That saves supports, finishing and money and gives a cleaner surface. Horizontal bridges over short distances (up to approx. 10 mm) usually succeed without support.

Tolerances for fits

If two printed parts should interlock or a part should fit a standard screw, plan for a little clearance. For a moving fit, around 0,4 mm of gap is a good starting value; for a tight press fit, about 0,2 mm.

Process

Ordering, payment & shipping

Once you've set material, color and quality, you add the part to the cart. You don't need an account for that, you can order as a guest and only provide the data we genuinely need for invoice and shipping.

Payment

We accept the usual payment methods for online purchases (all accepted payment methods are displayed in the footer) and purchases with an invoice via email for business customers. Payment is only due with the order; until then you can adjust the configurator as much as you like at no cost.

Production & shipping time

We print and dispatch small orders within 48 hours. How fast exactly depends on the quantity and size of your parts. A large batch naturally takes longer than a single part. Once your parcel is on its way, you'll get tracking by email.

Peace of mind

Print guarantee & returns

With contract printing the risk should sit with us, not you. That's why every order comes with our 30-day print guarantee: if a part is printed faulty, breaks in normal use despite an appropriate material and appropriate settings or doesn't match the uploaded model, we reprint it for free or refund you the full amount.

What's covered

• Visible print defects like detached layers, gaps or warped areas.
• Parts that don't match the geometry of your file.
• Breakage in intended use within 30 days despite an appropriate material and appropriate settings.

What's not covered

• Errors already present in the uploaded model (e.g. walls too thin that you ordered despite the warning).
• Material at its physical limit, such as PLA softening in direct sun.
• Damage from improper use or post-processing.

Filing a claim is simple: get in touch with your order number and a photo of the part. In the vast majority of cases it's resolved within one business day.

Troubleshooting

Common problems & solutions

My model is reported as "not printable"

Usually it's an unclosed volume or flipped faces. Fix it in your CAD or slicer software (e.g. with a "repair mesh" function). If you're stuck, send us the file; we'll look at it and come back with a concrete solution.

The displayed part is far too big or too small

This is almost always a unit problem (see chapter 1). Scale by a factor of 10 or 25,4 in the configurator. The latter converts inches to millimeters for example. Then check the dimensions again.

I don't know which material I need

Just take our default settings, you can't go wrong with them. Additionally, write what the part is for into the purpose box; we address that after the order. As a rough rule: PLA for looks, PETG for function, PC for the highest demands, TPU for flexibility.

The price seems high to me

Three levers lower the price noticeably: a coarser layer height, a lower infill and if possible a slightly smaller part. Just switching from "Fine" to "Medium" often makes a clear difference. Adding mutiples of one part also drastically reduces the setup cost

I need the part very urgently

Write to us before ordering. If we have free capacity we can prioritize rush orders and give you a realistic date in advance. This comes with a small extra fee.

Support

Still questions? How to reach us

This documentation covers most of it, but behind Filawerk are real people happy to help. Pick whichever way you prefer: