What Are Supports in 3D Printing and How to Optimize Them

Mar 54 min read

3D printing has changed manufacturing, enabling highly detailed and customized designs that were once difficult to produce. However, complex geometries often require additional structures in order to 3D print them successfully.

This is where support structures become essential. Knowing their purpose, types, and best practices is important for achieving high-quality prints with minimal material waste and post-processing effort.

What Are Supports in 3D Printing

A 3D printing support structure represents temporary structures used to uphold overhanging or intricate parts of a print that would otherwise collapse due to gravity. Many 3D models feature angles, bridges, or floating sections that lack a solid base for the layers above them. Without proper support, these sections may result in defects or print failure.

The need for supports depends on the printing technology and material used. While some 3D printers can print without additional structures by utilizing optimized orientation and slicing techniques, most require supports to maintain integrity. FDM (Fused Deposition Modeling) and SLA (Stereolithography) in most cases require supports, while SLS (Selective Laser Sintering) does not since it uses a powder bed that naturally supports the model.

Types of 3D Printed Support Structures

There are several types of 3D printing support structure, each with its own benefits and applications. Selecting the right type ensures ease of removal and minimizes material usage.

Some types of support structures differ in terms of their geometry, for example:

· Tree Supports

Tree supports resemble branching structures that only touch the model at key points. These are commonly used in resin printing and rarely used in FDM technology when complex details need support without excessive material use. Tree supports are easier to remove and consume less filament, reducing post-processing time.

· Linear Supports

Linear supports, or standard grid supports, are the most common type and are generated in a regular grid pattern beneath overhanging parts. These provide strong stability but often require additional post-processing due to their stronger attachment to the model.

Some support structures are designed based on their removal method after printing is complete, as follows:

· Soluble Supports

Soluble supports dissolve in specific liquids, such as PVA in water or HIPS in limonene, making them suitable for complex prints requiring clean finishes. These are often used with dual-extrusion 3D printers, allowing for intricate designs without the risk of damaging the model during removal.

· Breakaway Supports

Breakaway supports are designed to be manually removed after printing. They provide strong support but require careful detachment to avoid damaging the main structure. These supports are commonly used when soluble support materials are unavailable.

When a 3D Printing Support Structure Is Necessary

Determining when supports are needed helps balance material efficiency and print quality.

Several factors influence their necessity.

Angles of overhangs should be considered. Most FDM printers can print without supports if the angle is below 45 degrees. Angles that exceed this threshold require additional stabilization.
Distances of bridging impact print stability. Horizontal spans between two points, known as bridges, can often be printed without supports if the distance is short. However, longer spans require support to prevent sagging.
Orientation of the 3D model affects print success. Adjusting the model’s positioning in slicing software can reduce the need for supports. Aligning flat surfaces parallel to the build plate minimizes overhangs and floating sections.
Material type and properties determine whether supports are necessary. Some materials, such as PLA, work well with supports due to their stiffness, while flexible filaments can be difficult to remove from support structures.

If you are interested in learning more secrets about 3d modeling for 3d printing and achieve the best 3D printing results, please refer to our detailed guide creating 3d models for 3d printing.

Best Practices for Reducing the Need for 3D Printed Support Structures

Minimizing the use of supports reduces material waste and simplifies post-processing. The following strategies help optimize 3D prints by decreasing reliance on support structures:

· Optimize Model Orientation

Adjusting the orientation of the model in slicing software can significantly decrease the need for supports. Positioning overhangs to be self-supporting and aligning flat surfaces parallel to the build plate improves printability.

· Incorporate Self-Supporting Angles

Designing parts with overhangs that stay within a 45-degree angle prevents the need for additional supports. Using chamfers and fillets can further enhance stability without requiring extra material.

· Utilize Bridge-Friendly Design Techniques

Bridging techniques, such as reinforcing spans with thin ribs or arch-shaped structures, help maintain strength while avoiding the need for supports. Testing bridge lengths in small sample prints can determine the best approach for a specific material and printer.

· Modify Slicer Settings for Less Support Usage

Slicing software offers customization options to minimize support generation. Reducing support density, increasing the gap between supports and the model, or using tree supports instead of dense grid supports can reduce post-processing efforts.

· Split the Model into Multiple Parts

For complex geometries, breaking a model into separate printable sections that can be assembled later may eliminate the need for excessive supports. This approach works well for large prints with intricate overhangs.

Alternatives to Traditional 3D Printing Support Structures

While supports are necessary for many prints, alternative techniques can sometimes eliminate the need for them. These include:

Printing in Multiple Parts to Avoid Extensive Supports

Splitting a model into multiple sections and assembling them later can prevent the need for additional stabilization.

Designing with Self-Supporting Angles Can Minimize the Requirement for Supports

Adjusting model geometry to incorporate self-supporting angles and chamfers reduces reliance on external structures.

Using Adaptive Layering Helps Refine Print Quality

Some advanced slicers use adaptive layer heights to minimize the impact of overhangs, reducing the need for supports.

Achieving High-Quality Prints with Proper Support Management

Knowing what supports are in 3D printing and how to use them effectively leads to better print quality and less post-processing afterwards. By focusing on optimizing model design, adjusting slicing settings, and incorporating self-supporting features, unnecessary supports can be reduced. With advancements in slicing software and printing techniques, managing 3D printed support structures has become more refined, allowing for greater design freedom and improved results. For those looking for a local 3D printing service in Boston and across the MA, please feel free to contact us for any questions related to support structures and 3D printing services.