How to reduce the weight of 3D printed parts

In product development, every gram matters. Whether it’s improving battery life in a handheld device, cutting fuel burn in transport, or simply making a part easier to handle, reducing weight can deliver measurable gains. Additive manufacturing opens up approaches to weight reduction that traditional methods can’t match – from internal lattices to part consolidation – all without compromising performance.

Why lighter 3D-printed parts matter

Weight reduction isn’t just saving grams – it’s a performance lever.

• Energy savings: In transport, lighter parts reduce fuel or battery use over the product’s lifetime.
• Performance gains: Lighter parts are easier to move, which makes assemblies more responsive and can allow other components to be downsized.
• Simplified assemblies: Combining components into one printed part cuts hardware, assembly time, and failure points.
• Sustainability: Additive manufacturing uses only the material required, so lighter designs mean less waste.

Techniques for reducing weight

Hollowing and shelling

Removing internal material while keeping a uniform wall thickness is one of the most direct approaches.

• SLS generally builds without supports, though we may add local supports where needed. Hollow sections can be fully enclosed, with powder trapped inside if not vented.
• SLA and DLP need drain holes for resin removal. Orientation and supports affect how fine you can make the walls.
• Micro 3D Printing achieves thin walls down to tens of microns.

Lattice and cellular structures

Replacing solid cores with internal lattices maintains stiffness while cutting mass.

• SLS works well for enclosed lattices, with vapour smoothing to seal surfaces.
• SLA/DLP produce intricate lattices; DLP parts are non-porous and behave near-isotopically, ideal for fine struts.
• Micro 3D Printing on our BMF microArch S240 offers ~10 µm XY resolution, 1 µm positional accuracy, and 10–40 µm layers within a 100 × 100 × 75 mm envelope.

Topology optimisation

Software removes unneeded material based on your load cases, creating efficient, organic shapes that suit all PP AM processes.

Part consolidation

Merging multiple parts into one eliminates joints and hardware, often reducing weight and cost. Build size is the main constraint.

Material selection

Switching to lower-density materials while meeting functional needs is an effective lever.

• SLS: PA12 CR balances strength and weight for functional housings.
• DLP: Matrix PB10 (impact-resistant) or FR VO Black (flame-retardant) meet performance goals without excess mass.
• Micro 3D Printing: High-resolution resins for micro-scale parts.

A practical weight-saving workflow

1. Set objectives – Define your target weight and load limits.
2. Select strategies – Combine hollowing, lattices, topology optimisation, consolidation, and material choice.
3. Simulate – Use FEA to validate strength at each iteration.
4. Prototype – Produce samples in the chosen process.
5. Refine – Adjust thickness, lattice density, or materials.
6. Move to production – With weight, performance and manufacturability balanced.

How we support weight-reduced designs

We offer SLS, SLA, DLP, and Micro 3D Printing in-house, enabling you to choose the process that best matches your light-weighting goals.

• Instant online quoting via our Matrix platform for SLS, SLA and DLP; Micro and Filament 3D printing are quoted on request.
• Production speeds: Overnight, 3-, 7- or 12-working-day lead-times; next-day dispatch on SLS, SLA and DLP.
• Finishing options include bead blasting, lacquering, sanding/priming/painting, blackout/EMI/RFI coatings and vapour smoothing – all without adding unnecessary bulk.

From micro-lattices in handheld devices to consolidated aerospace brackets and optimised housings, our team will help you turn lightweight concepts into manufacturable, high-performance parts.

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