For typical features on the parts I design, I’ve done a bazillion tests to determine the ‘best’ parameters for Overhangs and Curves (especially curved overhangs).
I always prefer to avoid using Supports.
For my needs, that required designing some useful test parts that represent the challenges on typical features.
I dialed in the process such that I get absolutely perfect overhangs with PLA, ABS (and, to a somewhat lesser extent, with PETG).
I strive for Bridging without supports when the length is less-than about 22mm. That’s about the best/cleanest ‘Bridging’ length for me thus far. Photo of Bridging attached. Actual Overhangs (not bridging are shown in the photo of Table Holder).
Photo of Table holder with large overhangs (no supports were used) - Very clean underside of Overhangs!
Attached are test parts…
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3D Print Parts