How to Remove Supports from 3D Prints  

Removing supports is a key step in post-processing 3D prints. Supports help with overhangs and complex designs, but they must be carefully removed to avoid damaging the final print. This guide covers the best methods of how to remove supports from 3D prints and tips for cleaner results.

Step-By-Step Methods for Support Removal

Different methods of removing supports exist, depending on the type of support material and the complexity of the print. Here are a few:

Manual Removal

This is the most common method for single-extruder 3D printers, which enables prints where supports are made from the same material as the model (like PLA or ABS). 

1. Cool the Print: The print needs to be completely cooled and hardened before removal of supports, warm prints are typically more fragile and damage easily.
2. Start with Easy Supports: Remove easily accessible supports first by twisting or breaking them off by hand.
3. Use Tools for Precision: For more stubborn supports, use:

• Flush cutters – Cut supports at the connection points without damaging the model.
• Needle-nose pliers: You just grip and most likely twist the supports to cleanly break those chains off.
• Supports in internal areas: In hard-to-reach places, use a combination of flush cutters and pliers. Use flush cutters to cut then follow with pliers to remove the remaining pieces. 
• Be patient and careful: Work slowly to not scrape, dent, or break the model.

4. Smooth the Surface: After removing supports, refine rough areas with a file or sandpaper. Wet sanding helps achieve an even smoother surface.

Related reading: Improve Surface Finish: Sanding and Smoothing Your 3D Prints

If you have a dual-extrusion 3D printer, the breakaway support material would help with quick and easy removal. This would achieve a high-quality surface finish without further post-processing needs.

Dissolvable Supports (Chemical Removal)

If you have a dual-extruder printer, you can use special support filaments like PVA (water-soluble) or HIPS (dissolves in limonene).

1. Submerge the Print: Place the print in warm water for PVA or limonene for HIPS and let the solvent break down the supports.
2. Keep the Liquid Moving: Stirring the water or using an ultrasonic cleaner speeds up the dissolving process.
3. Be Patient. Allow enough time for the supports to fully dissolve. The process duration depends on their density and thickness.
4. Assist with Manual Removal: If necessary, let the supports soften for 10 minutes, then cut away larger sections before resubmerging.
5. Rinse and Dry the Print: After the supports are dissolved, rinse the model thoroughly with clean water to remove any residue and dry it completely. Avoid using very hot water, as it can warp the print.

Heat Assisted Removal

Applying heat softens the support material, making it easier to remove manually.

1. Use a Hair Dryer or Heat Gun: Heat at a low setting to prevent warping of the model.
2. Heat the Support in Short Bursts: Slowly heat the supports so that print does not become too soft or deformed.
3. Remove Supports While Warm: Once softened, supports can be broken or cut away more easily.

Using those Tools to Remove Supports

Having the right tools makes support removal easier and cleaner.

• Flush Cutters, Needle-Nose Pliers, X-Acto/Craft Knife, Tweezers, Dental Tools: These are essential for manual removal and are also very helpful in heat-assisted removal. Even when using dissolvable supports, you might use these tools to remove the bulk of the support structure before or during the dissolving process to speed it up, or to remove any stubborn remnants after dissolving.
• Files and Sandpaper, Deburring Tool: Basic post-removal finishing tools and useful regardless of how you originally remove supports Whether you manually cut, heat-soften, or dissolve supports, you’ll likely need these tools to smooth surfaces and remove any remaining nubs or imperfections.
• Heat Gun or Hair Dryer: Specifically for heat-assisted removal, but not used in manual or dissolvable support methods unless you are pre-softening supports before manual removal.
• Solvents (Water, Limonene): These are exclusively for dissolvable supports. They are this method’s primary “tool” as they chemically break down the support material.
• Ultrasonic Cleaner: This is most beneficial for dissolvable supports. It helps to agitate the solvent and remove dissolved support fragments more effectively, especially from intricate areas. It can also be used to clean prints after manual removal, but it’s not essential for other methods.

Tips for Easier Support Removal

• Optimize Print Orientation: Orient your 3D model in the slicing software to minimize the need for support. Printing models horizontally often means less support material and much compared to vertical printing. 
• Design with Supports in Mind: Design your 3D model, keeping it in such a way that supports will require the least. Chamfer, fillet, and flat surface wherever possible. 
• Adjust Slicer Settings:
  • Z-Distance: Adjust the Z-distance setting in your slicer. A larger Z-distance (the gap between support and model) makes supports easier to remove but might reduce surface quality. A smaller Z-distance improves print quality but makes supports harder to remove.   
  • Support Density: Lower support density makes removing supports easier and saves material. 10% density is often recommended, but you might need to increase it for steep overhangs.   
  • Support Interface: Enabling a support interface can create breaking points, making removal easier, but it might leave slight scarring that needs sanding.
  • Support Pattern: Grid or cross-support patterns are generally easier to remove than denser patterns like a honeycomb. Consider using tree supports, which are designed to be easier to remove and use less material, especially for complex geometries.   

Conclusion

Support removal is an integral part of achieving a clean and polished 3D print. Whether you use manual tool removal, dissolvable filaments, or heat-assisted techniques, these approaches will be worth it despite all efforts to ensure the quality of your model. Optimizing slicer settings and using the right tools provides a fast and easy way to remove supports.