Problem with supports for a complex/tricky model

[greghuber]

I am a new user to SImplify3d but experienced with 3d printing. I have an STL file that I imported. This model is a bit tricky- it has a lot of "gaps" in it, and the model needs supports in order to be printed correctly. I was hoping Simplify 3D would be smart enough to handle auto generating supports, but it doesn't appear to be able to. Here is a side view of the model:

http://imgur.com/D63zSul

When I try to auto generate supports (tried supports of size 1mm or 4mm) it puts about 10-15 supports on the model, and only in a certain area:
http://imgur.com/rqsRml2

As you can see in the image, it doesn't put all the supports where they would need to be, and the print quickly fails. I haven't yet gone through and manually mouse clicked to add supports, as that seems like it would take quite some time to do.

Any tips or pointers on what can be done?

[CompoundCarl]

It's pretty clear from those screenshots that there are some serious problems with your mesh. You need to fix the mesh first before you try to print it.

Try using a service like this to repair it: https://netfabb.azurewebsites.net/

[danielhenley]

I find it much easier to break a model up into multiple pieces that don't require supports and glue them together afterwards than to try to clean up a massive amount of support material.

[greghuber]

It's pretty clear from those screenshots that there are some serious problems with your mesh. You need to fix the mesh first before you try to print it.

Try using a service like this to repair it: https://netfabb.azurewebsites.net/

Thanks, I will give that a try. The person that designed the model is on vacation right now, but claims he can print it fine. I'm not sure what he is doing, perhaps he does some manual tweaking or has another model that he's using.

[greghuber]

I find it much easier to break a model up into multiple pieces that don't require supports and glue them together afterwards than to try to clean up a massive amount of support material.

I thought about doing that as well, but was not wanting to invest a lot of time in manually splitting the model up. Do you have any particular tool that you recommend to split things up? I am not a CAD expert but interested in learning some of the basics so I can do that type of thing.

[greghuber]

It's pretty clear from those screenshots that there are some serious problems with your mesh. You need to fix the mesh first before you try to print it.

Try using a service like this to repair it: https://netfabb.azurewebsites.net/

I just wanted to say thanks- this fixed my model and I was able to auto generate the supports, which led to a successful print. Thanks much for telling me about this resource! This is fantastic. Appreciate your help.

[danielhenley]

I find it much easier to break a model up into multiple pieces that don't require supports and glue them together afterwards than to try to clean up a massive amount of support material.

I thought about doing that as well, but was not wanting to invest a lot of time in manually splitting the model up. Do you have any particular tool that you recommend to split things up? I am not a CAD expert but interested in learning some of the basics so I can do that type of thing.

Manually breaking up the model requires some skill, meshmixer is a good tool for beginners.

Another reason I often break models up is for strength; FDM prints are only strong on one axis--so if you have a part that requires strength in multiple axis splitting it up and printing in different orientations and then gluing the pieces together will help greatly.