Hi,
I’ve designed a two-component object with a slide-in mechanism, similar to the design attached. However, I find that removing the supports is quite time-consuming—especially since I need to print hundreds of these parts.
Do you have any smart ideas for achieving a similar mechanism but with little to no support removal required?
How have you approached similar challenges?
Thanks Massimo
I would need to understand more constraints to suggest an alternative. I can think of a bunch of possibilities but I don’t know which ones make sense given your actual constraints. Generally, I would suggest reviewing the techniques in here:
One thing you could do if you are really constrained to this particular shape is modeled supports. You could model supports that are easy to break away, instead of accepting whatever the slicer gives you. I’ve used this technique quite a few times. For example, putting one-layer-thin walls on the side opening of the thicker block, and temporary 45-degree gusset supports on the piece on the right, might work well.
But if you want to redesign to require no supports at all, you’ll need to describe you constraints more. What kinds of motion need to be allowed, and which can be constrained? To what extent can the shape of the slot/tab be changed?
Thanks so much for your initial ideas and for sharing the link to this rich article. Let me try to respond:
The image is just a frame; They are the top open parts of U-shaped components.
The Top tab, together with the Base tab (right piece), ensures it doesn’t move up or down.
The tab/slot shape has no constraints, as long as the right piece doesn’t move up or down.
Let me know if I need to provide further clarification,
Thanks again
Well, do you literally want it to slide around in two axes on one plane, or is it merely for assembly? If it’s just for assembly, you can use features that print without support.
Could you make the tab and slot trapezoidal?
The old rule of thumb was that you could print 45° without problem, but really 30° works well with most modern printers.
I’d simply turn the right piece 90deg right so it sits on it’s right hand side. Likewise turn the left hand piece 90deg left so it’s sitting on it’s left hand side. That way no supports should be needed for either piece. Though it’d not be in the orientation they’ll end up in, that doesn’t really matter while they’re being printed.
Hi only added later in the comments but it has a U shape therefore I am not sure it works
Thanks anyway. other ideas ? 
Yes, you interpreted what I said in the way I meant it. It’s not obvious to me from your drawing of the U shape why it wouldn’t work — from how I interpret the drawing it looks better that way. Maybe I didn’t understand the context well enough?
I was only judging by the diagrams in the OP which seemed quite simple shapes, the added complexity in the latter diagrams confuse my solution somewhat.
Did I miss where it was stated it could only be printed as shown?
Why not eliminate all support and just print with the bottoms being what’s shown as the left and right sides in the original pictures.
Apologies, I clarified later in the comments that those two have a U-shape (see the design) therefore printing on those side it is not an option
Looks like an assembly which makes them “U” shaped which still means they can be printed on their side. If not an assembly then make them one so there’s no need for support.
You could also try printing in-place so that the outside part acts as the support for the inside part.
Set your Bridging speed really really low and make sure the part cooling fan is on 100% for bridging.
Another alternative might be printing them on end, which would likely succeed for both parts without supports, or with only minimal supports for what becomes an arch.
But none of that will work if layers need to be horizontal due to anisotropy
