Support structures are necessary for some 3D printing projects, but they can also increase the cost, time, and waste of your prints. How can you reduce the amount of support material and improve the quality of your prints? In this article, you will learn some tips and tricks to minimize support structures and improve printability in 3D printing.
One of the easiest ways to reduce the need for support structures is to choose the best orientation for your model. By rotating your model in the slicing software, you can avoid overhangs, bridges, and gaps that require support. Try to align the largest flat surface of your model with the build plate, and avoid placing delicate or detailed features on the bottom. You can also use the preview function of your slicer to check how much support material will be generated for different orientations.
Not only is orientation important for your typical 3D printing (FDM & Resin) but, it is important for powder bed fusion such as HP MJF. With MJF there are many factors to consider such as: ? Thermal sink ? Spacing of parts ? Part features Thermal sink occurs on the top side of your parts and can affect your tolerances, your parts need to be spaced far enough way from each other so they do not fuse, part features are sharper on their top surfaces and smoother on their bottom surface when printing with MJF. Typically if the surface is customer facing you should put that surface downward. If you need to preserve multiple sides then it's best to do the 30 30 method. Where you angle the part on the x and y axis 30°.
If you cannot avoid using support structures, you can still optimize the settings to use less material and make them easier to remove. Depending on your slicer and printer, you can adjust the density, pattern, distance, angle, and interface of the support structures. For example, you can use a lower density and a zigzag pattern for less material consumption, a larger distance and a smaller angle for easier removal, and a thin interface layer for smoother surface quality.
Another option to minimize support structures is to use custom supports instead of the automatic ones generated by your slicer. Custom supports allow you to place them only where they are needed, and to design them in a way that suits your model. You can use a 3D modeling software or a dedicated tool like Meshmixer to create and edit custom supports. You can also use tree-like supports that branch out from a single point and reduce the contact area with your model.
Designing in supports that do not need to be removed can help you achieve less removable support structure as well. For example, just design in a 45 degree ramp connecting to a lower area on your part instead of leaving the area as an overhang. Minimizing support removal where you can is better.
The type of material you use for your print can also affect the amount of support structures you need and how easy they are to remove. Some materials are more prone to warping, curling, or sagging than others, which can increase the need for support. Some materials are also more difficult to separate from the support than others, which can damage your print or leave marks. You can choose a material that has good dimensional stability, low shrinkage, and high tensile strength for your print, and a different material for your support if your printer allows it.
One more thing that I've found helpful is that if you have a two-nozzles head (or more), you can use a second type or different color of material. Thus, it will be easy to understand later what and where should be removed without damaging the original structure.
One of the most effective ways to minimize support structures and improve printability in 3D printing is to use soluble supports. Soluble supports are made of a material that dissolves in water or another solvent, such as PVA, HIPS, or BVOH. This way, you can print complex models without worrying about removing the support manually or damaging the surface quality. You just need to soak your print in a container with the appropriate solvent and wait for the support to dissolve. However, soluble supports are more expensive and require a dual extruder printer and careful storage.
I have used PVA for a number of print projects. It's pretty great. Sometimes it takes a little agitation of the water to get all the plastic all the way off (it dissolves quickly but into a slimy film that coats your part, so visual inspection isn't quite enough to really tell if it's off yet, you have to rub your fingers on it for a bit). And it's pretty stringy when it prints. But that should be fine if you're just using it as support material. Aside from that, it prints well. It does a great job of supporting the actual print. It's pretty soft so it comes off fairly easy from the print; sometimes I don't even need to immerse it in water.
Finally, the best way to minimize support structures and improve printability in 3D printing is to experiment and test different options. You can use test models or parts of your model to try different orientations, settings, supports, and materials, and see how they affect the print quality and the support removal. You can also use online resources and communities to learn from other 3D printing enthusiasts and share your results and feedback. By experimenting and testing, you can find the optimal solution for your 3D printing project.
You can also try to edit the model to include steady transitions from small cross-sections to large cross-sections to avoid overhangs. For example, instead of a 90° overhang, place a radius or 45° (or whatever angle works) slope under the overhang. This can provide the rigidity you need to avoid supports.
If your printer supports it by using two or more materials, mix slightly incompatible materials. Setup your main extruder to print your model out of your main material, I.e. PET, then use a secondary nozzle to print the support, I.e. PLA. With the proper printing, the incompatible materials will provide enough support to print, yet the incompatibility allows for easier removal of the different material's. This is an option to the more expensive soluble filament, if your specific design works with this method.