It all comes down to minimizing the amount of structural integrity you demand of your mesh before it's fully printed.

Since this thing is composed of a bunch of extruded squares, lots of its parts can just be laid out flat. The two curls will need supports added, which lots of free apps can do automatically.

Last night, though, I had to manually stitch some of this stuff together in Blender, so that the printer software would recognize overlapping geometries as parts of the same solid.

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