Escaping Tree-Support (ET-Sup): minimizing contact points for tree-like support structures in additive manufacturing

Support structures are often needed in additive manufacturing (AM) to print overhangs. However, they are the extra materials that must be removed afterwards. When the supports have many contacts to the model or are even enclosed inside some concavities, removing them is very challenging and has a risk of damaging the part. Therefore, the purpose of this paper is to develop a new type of tree-support, named Escaping Tree-Support (ET-Sup), which tries to build all the supports onto the build plate to minimize the number of contact points.,The methodology is to first classify the support points into three categories: clear, obstructed and enclosed. A clear point has nothing between it and the build plate; an obstructed point is not clear, but there exists a path for it to reach the build plate; and an enclosed point has no way to reach the build plate. With this classification, the path for the obstructed points to come clear can be found through linking them to the clear points. All the operations are performed efficiently with the help of a ray representation.,The method is tested on different overhang features, including a lattice ball and a mushroom shape with a concave cap. All the supports generated for the examples can find their way to the build plate, which looks like they are escaping from the model. The computation time is around one second for these cases.,This is the first time truly realizing this “escaping” property in the generation of tree-like support structures. With this ET-Sup, it is expected that the AM industries can reduce the manufacturing lead time and save much labor work in post-processing.