Exporting CAD Files for 3D Printing: A DesignWithAjay Tutorial

Exporting CAD Files for 3D Printing: A DesignWithAjay Tutorial

At Ajay Industries, we design with manufacturing in mind. Whether you’re prototyping a modular 

shredder component or a custom 3D-printed product, exporting your CAD file correctly is the key to a successful print. This tutorial walks 

you through the essential steps to prepare and export your CAD models for 3D printing—ensuring dimensional accuracy, printability, and professional results.

Why Exporting Matters

CAD models are rich with parametric data, but 3D printers require simplified mesh formats like STL, 

OBJ, or 3MF. Exporting correctly ensures:

• Accurate geometry and scale
• Clean mesh without gaps or non-manifold edges
• Compatibility with slicing software (e.g., Cura, PrusaSlicer, Bambu Studio)

Step-by-Step Export Workflow

1. Finalize Your CAD Model

Before exporting:

• Ensure all bodies are solid and watertight
• Remove unnecessary sketches, construction geometry, and hidden features
• Use “Check Geometry” tools to validate integrity

2. Set Units and Scale

• Confirm your model is in millimeters (mm)—the standard for most slicers
• Use global variables to control dimensions if needed

3. Export to STL or 3MF

In SolidWorks:

• Go to File > Save As
• Choose .STL or .3MF
• Click Options and set:
  • Resolution: Fine (for smoother curves)
  • Output as: Binary (smaller file size)
  • Units: Millimeters

In Fusion 360:

• Right-click the body or component
• Select Save as Mesh
• Choose format (STL, OBJ, 3MF)
• Set refinement level and units

4. Inspect the Mesh

Use a mesh viewer or slicer to:

• Check for holes, flipped normals, or intersecting geometry
• Validate wall thickness and overhangs
• Confirm orientation and part size

5. Slice and Print

Import into your slicer:

• Adjust layer height, infill, supports, and print speed
• Preview the sliced layers for any anomalies
• Export G-code and send to your printer

What You Get with DesignWithAjay CAD Files

Every downloadable CAD file from DesignWithAjay includes:

• Native CAD formats (.SLDPRT, .STEP, .IGES)
• STL and 3MF files for direct printing
• Exploded views and dimensioned drawings
• BOM with material recommendations
• Revision history and customization notes

Real-World Example: 3D-Printed Blade Spacer

Design Goal: Lightweight spacer for twin-shaft shredder CAD Model: Parametric SolidWorks part with fillets and chamfers Export Format: STL (binary, fine resolution) Print Material: PETG with 40% infill Outcome: Dimensional accuracy within ±0.2 mm, ready for functional testing