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<p>Additive manufacturing (AM) is a disruptive technology that enables the fabrication of intricate geometries layer-by-layer by discretizing the given geometry into multiple slices. Overhangs are regions of these slices where the surface projection exceeds the underlying horizontal support. AM techniques, like material extrusion (MEX), require explicit <i>support</i> structures, which are added to ensure proper printability and dimensional stability. Although supports provide part balancing to avoid material sagging, they should be minimised as they increase the overall material usage, print time and associated costs. Limited studies have been done on the self-supporting capacity of thin-walled AM structures. This research presents a novel analytical model based on the beam bending principle to determine the material’s limit to self-sustain overhangs. The model determines this limit in terms of an overhang angle (from the vertical) using part geometry, process parameters and material properties. It is found that the overhang angle has an inverse square root relation with an <i>apparent</i> number of layers, which can be linearly approximated as a function of the number of layers. The model is further extended to incorporate buckling effects in the extruder fibres. Analytical results showed that overhangs as high as 75<sup>o</sup> are possible without any external supports, as against the conventional 45° limit. The presented model can alleviate the AM process by increasing the printing efficiency and reducing material wastage.</p>

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A mechanistic model for overhang limits in additive manufacturing

  • 期刊论文

  • 发表日期：

    2025年5月17日

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  • Yash Mittal,
  • Vedant Agarwal,
  • Dixita Yadav,
  • Kossi Loic Avegnon,
  • Michael Sealy,
  • Pushkar Kamble,
  • Gopal Gote,
  • Yogesh Patil,
  • Avinash Mehta,
  • Paras Mandal,
  • K. P. Karunakaran

摘要

Additive manufacturing (AM) is a disruptive technology that enables the fabrication of intricate geometries layer-by-layer by discretizing the given geometry into multiple slices. Overhangs are regions of these slices where the surface projection exceeds the underlying horizontal support. AM techniques, like material extrusion (MEX), require explicit support structures, which are added to ensure proper printability and dimensional stability. Although supports provide part balancing to avoid material sagging, they should be minimised as they increase the overall material usage, print time and associated costs. Limited studies have been done on the self-supporting capacity of thin-walled AM structures. This research presents a novel analytical model based on the beam bending principle to determine the material’s limit to self-sustain overhangs. The model determines this limit in terms of an overhang angle (from the vertical) using part geometry, process parameters and material properties. It is found that the overhang angle has an inverse square root relation with an apparent number of layers, which can be linearly approximated as a function of the number of layers. The model is further extended to incorporate buckling effects in the extruder fibres. Analytical results showed that overhangs as high as 75o are possible without any external supports, as against the conventional 45° limit. The presented model can alleviate the AM process by increasing the printing efficiency and reducing material wastage.