Algorithmic Support Generation and Verification: Optimisation Objectives, Constraint Conflicts, Simulation and Human Override

Supports simultaneously influence build stability, surface damage, material use, removal effort and failure risk. Overhang angle, island formation, peel force, thermal distortion and recoating constraints differ across AM processes. Mechanical or process simulation can rank candidate support layouts, but predicted stress or deformation depends on uncertain material state, boundary conditions and layerwise process assumptions. Expert intervention remains valuable for inaccessible cavities, cosmetic surfaces and removal strategy. Checking that supports exist at nominated locations is insufficient. Qualification therefore depends on preserving the measured state, configuration and exception history needed to distinguish these mechanisms in production rather than relying on nominal recipe identity alone.

ER-346.