Section outline

  • Support Material Principles

    When designing parts for 3D printing, especially for robotics, you may encounter overhangs or complex geometries that cannot be printed in mid-air. This is where support materials come in. In this section, we’ll understand what support structures are, when they are needed, and how to optimize them for clean and successful prints.

    • What Are Support Materials?

      Support materials are temporary structures printed along with your main object. They provide physical support to overhanging parts that would otherwise sag or collapse during printing.

      When Are Supports Required?

      • Overhangs greater than 45°: Anything steeper generally needs support
      • Bridges: Flat horizontal parts between two points (limited span can be done without supports)
      • Floating Elements: Any parts of the model that are suspended mid-air

      Types of Support Structures

      • Grid: Strong and widely used, but harder to remove
      • Lines: Easier to remove but less supportive
      • Tree (Organic): Branch-like supports, useful for minimizing contact with the model

    • Best Practices for Using Supports

      • Design parts with as few overhangs as possible to minimize the need for support
      • Orient the model to reduce unsupported angles
      • Use support blockers in slicer software to exclude unnecessary areas
      • Enable ‘support interface’ layers for cleaner separation
      • Use soluble supports (e.g., PVA) with dual-extruder printers for easier removal

      Example Support Settings Table

       

      Setting Recommended Value Purpose
      Support Overhang Angle 45° Supports enabled beyond this angle
      Support Pattern Lines/Grid Choose based on ease of removal vs. strength
      Support Density 15% Balance of strength and material saving
      Z Distance 0.2 mm Gap between support and model for easy removal

      Removing Supports

      • Use pliers or flush cutters for larger supports
      • Sanding or filing can help smooth leftover marks
      • Use warm water to dissolve PVA supports if used
      • Be gentle—rushing support removal can break delicate parts

      Support materials are essential for printing complex shapes, but with good design practices and slicer settings, you can keep them minimal and manageable. Learning how to work with supports will allow you to design more creative and functional robotic parts.