Enhanced support structures in conformal additive manufacturing for improved geometric accuracy

In modern three-axis additive manufacturing, optimizing support structures is essential for achieving a balance between material efficiency and geometric accuracy. Excessive support density leads to wasted time and material, while insufficient density can cause geometric errors and unsupported regions. This study presents a new method that aligns support design with print-path geometry, ensuring that the maximum support distance is maintained to avoid unsupported sharp points. This research primarily focuses on support structure design for parts printed using conformal print-paths, with potential applicability to concentric print-paths as well. Tested on eight different test cases, the method achieved an average reduction of 16% in support volume and a 73% improvement in geometric accuracy compared to standard approaches.