Minimum wall thickness depends on the technology: 1.2mm for FDM, 0.8mm for SLA (1.5mm unsupported), 1.0mm for Industrial SLA, 0.7mm for MJF (1.3mm preferred), and 2.0mm for FGF. Too thin and the part can fail during printing or break during handling; too thick and you waste material and increase cost.
Recommended minimum wall thickness
FDM (PLA, PETG, TPU, ASA, PC CF)
- 1.2mm minimum
SLA
0.8mm minimum
1.5mm for unsupported walls
Industrial SLA
1.0mm minimum
2.0mm for medium parts, 3.0mm for large parts
MJF (Nylon PA12, PA11, PA12 Glass Filled)
0.7mm minimum, 1.3mm preferred
7.0mm maximum
FGF (ABS)
- 2.0mm minimum (larger nozzle requires thicker walls)
When to go thicker
Structural parts bearing load: 2–4mm+
Large flat panels: 3mm+ to prevent warping
Parts that will be sanded: Add 0.5mm for material removal
Outdoor parts: Extra thickness compensates for UV degradation
FGF parts: 5mm+ recommended for structural applications
Parts with snap fits or hinges: Follow specific design guidelines for those features
When you can go thinner
Small, non-structural features (tabs, labels): the technology minimums above still apply
Decorative elements not under load
Common mistakes
Inconsistent wall thickness — Sudden changes cause internal stress and warping. Transition gradually.
Zero-thickness walls — Overlapping surfaces in CAD that look solid but have no actual thickness. Run a wall thickness analysis in your CAD software.
Thin walls on large parts — What works on a 2-inch part may warp on a 12-inch part.
Pro tip
Most CAD software has a wall thickness analysis tool. Run it before exporting your STL. In Fusion 360, use Inspect > Section Analysis. In SolidWorks, use Evaluate > Thickness Analysis.
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