What type of AM part may require extensive post-processing, including support structure removal?

An AM part that may require extensive post-processing, including support structure removal, is typically one that involves complex geometries and the necessity for support during the printing process. In the case of directed energy deposition (DED), this technology often involves adding material layer by layer, and due to the nature of the process, parts can have features that require significant support structures to maintain their shape while being built.

When these parts are printed, the support structures are generally not part of the final product and must be removed afterward to achieve the desired finished state. This can involve extensive machining or manual labor to ensure that the end-use part is within the required specifications and surface finish.

In comparison, while other methods like stereolithography (SLA) and material jetting can also require some degree of post-processing, they typically have different needs. For instance, SLA may produce a part without extensive supports when designed appropriately, whereas material jetting is often used for detailed, high-resolution surfaces that may not require heavy supports. Functional models made via binder jetting also tend to be less reliant on supports due to their design and the materials used. Thus, DED is specifically noted for the necessity of significant post-processing due to support removal.