• Part size. Consider components with a size similar to or smaller than a tennis ball as a reference.
• Geometry. Consider components of complex geometry that contain internal channels, voids, overhangs, etc.
• Resolution. Consider components with fine details such as knurling, logos, grids, narrow grooves, small knobs, etc.

• It is recommended to rest parts on a flat surface during the sintering process to provide maximum support in the heaviest areas, with the goal of minimizing distortion.
• In cases where designing with a flat surface is not possible and significant distortion is anticipated, it is recommended to sinter parts on setters that accommodate their shape.

• Uniform wall thicknesses are recommended in order to prevent deformations and reduce dimensional variability, or design the part with gradual transitions between sections of different thickness if it is not possible.
• In general, design parts with a wall thickness greater than 1 mm for outer walls and greater than 5 mm for protected inner walls. In specific cases, the range can be extended to a minimum of 0.3 mm and a maximum of 30 mm.

• Generating hollow sections in components requires the evacuation of excess powder during the depowdering step, so powder evacuation holes must be incorporated into the design.
• In general, a minimum of 2 evacuation holes should be used, though the final number depends on the volume and diameter of the hollow section.
• The diameter of the evacuation holes should be as large as possible in order to facilitate proper depowdering of the component without compromising its structural strength; in general, they would be > 0.5 mm for blind or through holes, and about 5 mm for holes that lead to internal cavities or channels.
• If the part contains pins, it is recommended that they have a diameter greater than 1.5 mm and with a ratio of 10:1 with respect to their length.

The design of thin sections, slender shapes and overhangs requires the use of ribs, gussets, webs and other reinforcements. The objective is to increase the rigidity and strength of the components, to enable/facilitate processing, to improve dimensional stability, and to prevent the part from collapsing or being deformed. The thickness of the reinforcing elements should ideally be 40 to 60% of the thickness of the section where they are positioned, and their length should not exceed 3 times their thickness.

A certain range of complete inner and outer threads can be obtained without the need for machining. It is advisable to avoid fine pitch threads, to minimize their length and to design the component so that the thread is located in a favourable position to minimize the effects of anisotropic shrinkage during sintering.

• The dimensional precision is considerably better than that obtained by powder bed fusion processes and similar to that achieved by Metal Injection Molding.
• General tolerances: ±1.3% for a nominal dimension of 30 mm in 5σ.

• Metal Binder Jetting process allows for the production of components with an as-sintered surface roughness of around 6 Ra, without the need for additional post-processing.
• The surface finish can be enhanced through certain post-processing operations, similar to metal parts manufactured using other technologies.