In 2013, I worked on a project for Makerbot's innovation division (Bold Machines) trying to push the 3D printers to their limit. I created a full cast of characters that had to be made of parts to be printed in their Replicator 3D Printer with minimum amount of supports.
FDM printers can be pretty challenging for character design.
This character is the Shorter Bridge Construction Worker who made a comic duo with his bigger brother (who you can find on the gallery).
In the images at the bottom you can see how all parts have a flat side in order to be able to be placed on the 3D printer plate and use minimum supports. Also, you can see the assembly scheme of all the parts.