A part too big to print is a design decision, not just a slicer setting
When a part exceeds the build volume in every orientation, the impulse is often to just "split it in the slicer," but that treats what is really a design decision as a mechanical afterthought. Three genuinely different paths exist: print as one piece (only possible if it fits), split and join with some kind of interface, or step back and redesign the part as an intentionally modular assembly from the start. Each has different consequences for strength, appearance, and how much assembly work you take on.
How the comparison works
If the part already fits the build volume and is not strength-critical, printing as one piece is the clear best fit. If it needs to split and is strength-critical with low tolerance for extra assembly work, a straightforward split-and-join is favored over a full redesign. If it is both oversized and strength-critical, with more tolerance for assembly labor, a genuine modular redesign is offered as the strongest long-term path, since it lets each section be engineered on its own terms rather than bolted together after the fact.
Worked example
A part that exceeds the build volume, is structurally load-bearing, with only low tolerance for extra assembly labor: split-and-join is recommended as the best fit, since a full redesign is the stronger long-term answer but is not practical given the low labor tolerance stated; a keyed or reinforced joint is suggested to offset some of split-and-join's strength weakness.
A common mistake
A frequent error is choosing a split line for slicer convenience (wherever the model happens to fit two build plates) rather than for the joint's actual structural or cosmetic consequences. A split placed at a high-stress cross-section can turn a strong single-piece design into a weak two-piece one; plan the split location deliberately, not as a leftover decision after everything else is finalized.
Limitations
This compares the three paths qualitatively based on what you entered; it does not calculate joint strength or alignment tolerance for your specific geometry. For a strength-critical split, validate the joint design with a real test piece before committing the full part.