Figure 1: The support material generated by the built-in 3D printing software for MakerBot R Replicator TM 2 a) and the amount of support material b). Our solution c) reduces the amount of the support material d), leads to faster printing, and higher quality of the fabricated model. AbstractWe introduce an optimization framework for the reduction of support structures required by 3D printers based on Fused Deposition Modeling (FDM) technology. The printers need to connect overhangs with the lower parts of the object or the ground in order to print them. Since the support material needs to be printed first and discarded later, optimizing its volume can lead to material and printing time savings. We present a novel, geometry-based approach that minimizes the support material while providing sufficient support. Using our approach, the input 3D model is first oriented into a position with minimal area that requires support. Then the points in this area that require support are detected. For these points the supporting structure is progressively built while attempting to minimize the overall length of the support structure. The resulting structure has a tree-like shape that effectively supports the overhangs. We have tested our algorithm on the MakerBot R Replicator TM 2 printer and we compared our solution to the embedded software solution in this printer and to Autodesk R Meshmixer TM software. Our solution reduced printing time by an average of 29.4% (ranging from 13.9% to 49.5%) and the amount of material by 40.5% (ranging from 24.5% to 68.1%).

Abstract

a)b) c) d) Figure 1: A model of a dragon was first hollowed to reduce stress caused by its weight if held by the head (a). The stress decreased, but the neck had to be still thickened (b,c). The object was still too front heavy causing a twist deformation on the legs (c), that was eliminated by fixing the model to the pedestal by a strut (red) (d). These steps were done automatically by our system. AbstractThe use of 3D printing has rapidly expanded in the past couple of years. It is now possible to produce 3D-printed objects with exceptionally high fidelity and precision. However, although the quality of 3D printing has improved, both the time to print and the material costs have remained high. Moreover, there is no guarantee that a printed model is structurally sound. The printed product often does not survive cleaning, transportation, or handling, or it may even collapse under its own weight. We present a system that addresses this issue by providing automatic detection and correction of the problematic cases. The structural problems are detected by combining a lightweight structural analysis solver with 3D medial axis approximations. After areas with high structural stress are found, the model is corrected by combining three approaches: hollowing, thickening, and strut insertion. Both detection and correction steps are repeated until the problems have been eliminated. Our process is designed to create a model that is visually similar to the original model but possessing greater structural integrity.

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