Why is it important to limit the number of support structures and place them strategically in additive manufacturing?

Limiting the number of support structures and placing them strategically is crucial in additive manufacturing because improperly designed or excessive supports can lead to defects during the removal process. When supports are not managed carefully, their removal can cause stress concentrations, leading to warping, surface damage, or even structural failure of the part itself.

Strategically placing supports can mitigate these risks by ensuring that they are positioned in a way that minimizes their impact on the final part's integrity. This allows for easier removal while maintaining the desired surface finish and dimensional accuracy of the printed object, ultimately resulting in a better-quality product.

While reducing material waste is certainly a benefit, the primary concern is ensuring that the final part is not compromised due to the stress or damage incurred during the support removal process. Enhancing aesthetic appearance and improving thermal properties are secondary considerations and may not directly relate to the strategic placement of supports in most cases.