DFAM incorporates tools and processes that go beyond simply ensuring the part is printable. For parts larger than the printer bed, they are divided into sections and joined using interlocking methods. This research tested four types of beams (U-beam, H-beam, hollow beam, and bar beam) made from HSLA material with three types of loading (bending, axial, and torsion). The interlocking mechanism used male-to-female locking with variations in the male locker length. Stress analysis was conducted using Inventor. Results showed the best mechanisms: U beam-male locker length of 10 cm with the fastener position 5 cm from the base; bar beam and H beam-male locker length of 10 cm with the fastener position 1.67 cm from the base; and hollow beam-male locker length of 5 cm with the fastener position 1.67 cm from the base. These lengths and positions yielded the largest safety factors, making them suitable for …