Fused-deposition-material 3D-printing procedure and algorithm avoiding use of any supports

The three-dimensional printing of complex shapes without using supporting structures is the most attractive factor of merit in current additive manufacturing because it allows to drastically reduce printing time, and ideally nullify postprocessing and waste material. In this work, we present an innovative procedure and algorithm (Print on Air, PoA) for additive manufacturing that, relying on sensing systems embedded into the three-dimensional (3D) printer (e.g., temperature and speed sensors), aims at generating a printing sequence capable of a self-sustaining bridge and overhang structures. This feature was achieved by splitting the actual floating area of the layer where the aforementioned structures are in many subsections. Each is generated with a negligible floating surface and printed in a well-determined sequence with accurate temperature and speed profiles. Therefore, each subsection is formed without the need for scaffolding, simultaneously acting as a supporting structure for the following subsection. The array of subsections constitutes the actual bridge or overhang structure. The proposed method can be used for any object, including very long bridges or convex surfaces. The revolutionary method is here reported and evaluated in order to show its applicability in any condition. Although the study was conducted in a Fused Deposition Material (FDM) environment, it can certainly be adapted to other manufacturing environments with adequate modifications.