How to Add Support Structures for 3D Printing in SolidWorks

To add support structures for 3D printing in SolidWorks, create custom geometry such as extruded or lofted shapes under overhangs that need support. Use features like Boss-Extrude or Surface tools to design supports manually, as SolidWorks does not have automatic support generation like dedicated slicer software.

Syntax

In SolidWorks, support structures are created by adding new features to your model. The common features used include:

• Boss-Extrude: Adds solid geometry to create support pillars.
• Surface Tools: Create thin surfaces to act as support bases or connectors.
• Loft or Sweep: Create smooth, angled supports between the model and build plate.

These features are combined to build custom supports where needed.

text

1. Select the face or plane where support starts.
2. Use Boss-Extrude to create a pillar.
3. Use Loft or Sweep to connect support to the model overhang.
4. Adjust dimensions to ensure stability.
5. Combine supports with the main body using Combine or Boolean operations if needed.

Example

This example shows how to add a simple support pillar under an overhang using Boss-Extrude:

text

1. Open your part in SolidWorks.
2. Select the bottom plane or a plane near the build plate.
3. Sketch a circle where the support pillar will be.
4. Use Boss-Extrude to extrude the circle upward to meet the overhang.
5. Optionally, use Fillet to smooth the connection.
6. Save the part and export for 3D printing.

Output

A solid cylindrical support pillar appears under the overhang, providing physical support during printing.

Common Pitfalls

• Not checking overhang angles: Supports are needed only where overhangs exceed your printer's capability (usually >45°).
• Supports too thin or weak: Thin supports may break during printing; ensure adequate thickness.
• Supports merging with model: Avoid merging supports permanently if you want to remove them after printing.
• Ignoring build plate contact: Supports must touch the build plate to be effective.

text

Wrong way:
- Creating supports that do not reach the build plate.
Right way:
- Ensure supports start from the build plate and connect firmly to the overhang.

Quick Reference

Feature	Purpose	Tip
Boss-Extrude	Create solid support pillars	Use circles or rectangles for base shapes
Loft/Sweep	Create angled or curved supports	Connect base to overhang smoothly
Fillet	Smooth support connections	Prevents stress concentration
Surface Tools	Create thin support bases	Use for minimal material usage
Combine	Join supports with model if needed	Avoid if supports must be removable

Key Takeaways

Manually create support structures in SolidWorks using Boss-Extrude and Loft features.

Ensure supports start from the build plate and reach all overhangs needing support.

Check printer overhang limits to add supports only where necessary.

Keep supports thick enough to be stable but easy to remove after printing.

Use fillets to smooth connections and reduce stress points.