Geometry Based Volume Reduction of Support Material for Rapid Prototyping Processes

The emerging technology in manufacturing is Rapid Prototyping, by which one can fabricate the functional testing parts within less time. Rapid Prototyping (RP) includes different techniques viz., Stereolithography (SLA), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), 3D Printing etc., In some RP processes, the extended portion of the part needs the support material. The support materials differ from part material, which is useful only for supporting purpose. After fabricating the parts the support material has to be discarded from the part. As per the cost criteria, the cost of the support materials ranges between 30-40% of the total cost depending on the geometries. While fabricating the part, the support material has to sustain the weight of the extended parts and its forces. The thermal stresses induced in the support material due to difference in temperatures of part and support material while solidifying process should also be taken into consideration. The paper concentrates on the volume reduction of the support material for basic geometries without losing the functional requirements of the support material. Finite Element Method has been applied for stresses and thermal analysis. The values thus found conclude that there is a possibility to reduce the volume of the support material for about 10-15% depending on geometry of the part and thereby reduces the cost of fabrication.