A DfAM objective to redesign part geometry or orientation so that support structures are avoided or minimized, reducing print time, post-processing labor and surface damage at support interfaces.
Supports are waste: they consume material, add print time, require mechanical removal and leave surface artifacts. Design strategies to avoid them: (1) orient the part so overhangs face upward or are < 45° from vertical; (2) replace flat overhanging surfaces with chamfers or self-supporting arcs; (3) split complex parts at natural flat parting planes and bond after printing; (4) choose powder-bed technologies (SLS, MJF) that need no supports by nature.
For DMLS, supports are unavoidable for large horizontal overhangs but can be minimized with lattice supports (easier removal, less surface damage) and strategic orientation. For FDM, teardrop holes and 45° chamfers eliminate most support needs. In SLS/MJF, parts can be stacked and nested in 3D since all surfaces self-support: this dramatically increases build density and cost efficiency.
Zero-support designs for DMLS still require support at the base for heat dissipation: never attach directly to build plate without any anchoring. Eliminating supports by changing orientation may expose a weaker Z-direction to the primary load: always verify mechanical implications. Lattice supports in DMLS are preferred but their removal requires specialized tools and leaves small witness marks.
Related terms: Design for Minimal Material, Lightweighting / Mass Reduction, Part Consolidation
| Theme | optimization |
|---|---|
| Also called | support-free design, self-supporting geometry, support reduction |
| Source | Wiki/concepts/dfam.md, Wiki/tech/dmls.md |
Engineer, author of The Big Book of 3D Printing and additive manufacturing expert