Following our previous comparison of three 3D printing technologies , which received a great response, Sandima is now exploring the differences in the "support structure" of FDM printing to understand the various aspects that affect the final result. (Further reading: Beginner's Guide - Comparison and Principles of Common 3D Printing Technologies )
Since 3D printing creates objects by stacking layers, and materials tend to fall when suspended in mid-air, the auxiliary structures added at these points are called "supports." These supports are then separated from the main body after completion. Taking a fully movable Buckyball as an example, the final product of 3D printing should achieve the effect shown in the image: each layer can rotate, and the movement is smooth with minimal resistance.
Firstly, the most common FDM technology on the market mainly consists of two types of 3D printing : single-head and dual-head. A single-head system can only use one type of filament at a time, so the support material is the same as the print body. If a single-head FDM 3D printer uses PLA material to print "Buckyballs," the following result will be obtained: because the sphere has five layers, with each layer only 0.3 cm apart; with the support and the print body tightly bonded, the support is almost impossible to remove, or it may damage the print body.
The advantage is that it has little impact on large-area structures and is relatively easy to dismantle. For example, the suspended part of the ski goggle frame in the picture can be made using a single nozzle system. However, the surface smoothness and aesthetics will not be as good as those of a dual nozzle 3D printing system.
(The left image shows a ski goggle frame 3D printed using a single nozzle; the right image shows a ski goggle frame 3D printed using a dual nozzle with water-soluble support PVA (white part) and the finished product after dissolution.)
Dual-head FDM 3D printers can use two types of filaments simultaneously, allowing different filaments to be used for the body and support respectively. As seen in the time-lapse photography below, in Ultimaker's dual-head 3D printer, the object's body and support material are printed synchronously. The support structure is also automatically generated based on the object's body in the free official software Ultimaker Cura, eliminating the need for manual construction.
The white part is PVA , a biodegradable, water-soluble material. When printed with a PLA structure, it can be dissolved by immersing the entire structure in cold water (the process can be accelerated by about twice if an air pump or ultrasonic vibration is used to increase the water flow). After printing, the object can be removed and cleaned directly. This is the most popular method in dual-printer systems (the sticky feeling may not be eliminated if a non-independent dual-printer 3D printer is used).
Because the process does not cause physical damage to the surface of the object, the finished product surface is smoother and more beautiful than that of a single-nozzle 3D printer , making it particularly suitable for industrial parts such as assemblies and tenons that require precision.
Another Breakaway support offers excellent disassembly and disassembly speed, but it is more suitable for disassembling large areas of objects. For example, the electric drill casing in the picture below has aesthetic requirements, so only Breakaway support material needs to be used to assist in printing to achieve the effect of quick disassembly of the whole piece.
If budget is limited, it's recommended to prioritize the characteristics of the most commonly used 3D printed objects. For example, high-consumption, simple-structure auxiliary tools are better suited for single-head printers; while sample development with numerous styles and high future variability is more suitable for dual-head 3D printers ; or, both can be used together to achieve both innovative development and reduced production time. (Further reading: A direct look at "Club 5 - Brother Wu's Den of Addiction"! From distributing models to modifying and exporting! )
| Single-head 3D printer | Dual-head 3D printer | |
| Support form | • Single material • Same as the print body (commonly PLA) | Water-soluble PVA Quick-release Breakaway Other dual-material combined applications |
| Scope of application | Large-area support; simple structure; rapid mass production. | • Movable structural components. • Intricate details of the objects. • Requires maintaining a fine surface finish. |
Single - head 3D printers : These are typically suitable for producing simple printed objects or for small-scale production and development, and are relatively inexpensive.
Dual-head 3D printers are suitable for samples with complex structures and aesthetic requirements. They feature newer technology, more functions, and are relatively expensive.
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Ultimaker Single-Head 3D Printer 
Ultimaker Dual-Head 3D Printer
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