Optimized material extrusion on configurable and discretized platforms: a novel system for Support-Reduced additive manufacturing

Purpose 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. Design/methodology/approach 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. Findings 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. Originality/value 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.