This study aims to reduce the material consumption, print time, and cost associated with the extensive use of support structures in fused filament fabrication (FFF), a common additive manufacturing (AM) process. To achieve this goal, it introduces the Minimized-Support FFF (MSFFF) system, an innovative extrusion-based technique that integrates configurable and discretized and platforms into conventional FFF systems. The MSFFF system addresses the limitations of existing discrete-platform approaches by eliminating dedicated actuators, reducing complexity and enhancing adaptability.
The MSFFF system incorporates a passively elevated platform. The printer’s stepping motor primarily controls the height, while a small motor in the extruder housing activates the lifting motion. This approach avoids the use of additional power sources or control modules in the platform setup. A one-way locking mechanism secures the platform at precise heights with minimal energy consumption. A support-minimization strategy compatible with standard slicing software was developed, optimizing platform positioning based on part geometry. System performance was evaluated using test cases with overhang angles up to 90°, comparing material consumption, fabrication time and geometric accuracy against conventional FFF methods.
Experimental results demonstrated up to 36% reduction in total material consumption, up to 87% decrease in support material usage, and up to 33% reduction in overall fabrication time, with a 72% decrease in support structure printing time. The MSFFF system maintained high geometric fidelity across complex geometries.
By emphasizing modularity and ease of integration, the MSFFF system enhances efficiency and sustainability in FFF-based AM. The near-complete elimination of support structures presents significant potential for broader industry adoption, particularly in applications demanding optimized material usage.
