Three print fails, three lessons

Printer failures taught us more than tutorials. Three real cases from recent projects and the checklist they produced.

Fail 1: the double-sided wall

A model with two coincident walls sliced into overlapping shells and delaminated mid-print. Lesson: merge vertices, verify shells, never trust "it looks solid on screen".

Fail 2: the zero-thickness spike

A decorative spike thinner than the nozzle produced spaghetti. Lesson: minimum feature size must match the printer, not the render.

Fail 3: the unsupported overhang

A model printed fine once and failed on a different machine. Lesson: we now deliver with support notes per orientation, not just a watertight mesh.

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