Toward Support-Free 3D Printing: A Skeletal Approach for Partitioning Models

Minimizing support structures is crucial in reducing 3D printing material and time. Partition-based methods are efficient means in realizing this objective. Although some algorithms exist for support-free fabrication of solid models, no algorithm ever considers the problem of support-free fabrication for shell models (i.e., hollowed meshes). In this paper, we present a skeleton-based algorithm for partitioning a 3D surface model into the least number of parts for 3D printing without using any support structure. To achieve support-free fabrication while minimizing the effect of the seams and cracks that are inevitably induced by the partition, which affect the aesthetics and strength of the final assembled surface, we put forward an optimization system with the minimization of the number of partitions and the total length of the cuts, under the constraints of support-free printing angle. Our approach is particularly tailored for shell models, and it can be applicable to solid models as well. We first rigorously show that the optimization problem is NP-hard and then propose a stochastic method to find an optimal solution to the objectives. We propose a polynomial-time algorithm for a special case when the skeleton graph satisfies the requirement that the number of partitioned parts and the degree of each node are bounded by a small constant. We evaluate our partition method on a number of 3D models and validate our method by 3D printing experiments.