Unable to Remove Support  

RE:

Please examine the attached modified project.

A few points. 

1)This case design will have a layer that cant be supported (it is too close to the bed) and that is a steep overhang.  This is due to the curve design which is a common error when designing for 3d print.  Curves like that should never be printed face down, designers forget this.  It would print in a different orientation but doing that would lead to lots of support etc.  If you are willing to live with the print artefact this will have then ok.

2)Your painted supports were just applied by angle, rather than actually using some human discrimination in where they are painted.  That means your recessed text facing the bed was also painted as well  as the recessed text on one end (for Boot and Reset).  The areas of text do not need support, and in fact due to the size wont actually get any generated support so having them painted is pointless and can cause other problems.

3) and this is your main problem.  You have the first layer expansion for supports set to 3.5mm.  So that's what's being applied on the bed, the stuff you wanted removing.  It doesn't matter if its not actually connected to the support above.  PS works downwards,  So iut generates the interface layers (where it can), then it adds in the support downwards.  Then it expands that first layer. 
Remember I mentioned the angle that cant be supported as its too close to the bed.  Well as there is actual support above that area it gets included in the first later expansion.  Same with the text for boot/reset. 

There's a little bug-ette in the support generation where it doesn't remove stuff that's not actually being used once its followed the rest of its machine logic to generate the rest of it.  

The attached project has manually defined support areas and the settings tweaked.  So no more extraneous bits.

Also painting doesn't work like you think it does.  You are defining areas on the model where to place or not place support.  Once that happens the rest you have little control over.  You cant define somewhere higher up for support and then block if further down.  It will go down right through your 'blocked' area.  They are not keep out areas as such.  Defining something as needing support takes priority over not supporting when they would be mutually exclusive.

RE: Unable to Remove Support

I have so much to learn, it's honestly a little overwhelming.  It didn't even occur to me to change the print settings for support materials :(.

Regarding point 1, is there a preferred design method for creating a rounded corner for a case?  I was thinking just a 45-degree bevel, not sure what is the better option or best option which applies to 3d printing.

Thank you so much for your detailed explanation!

Kindest regards

RE: Unable to Remove Support

When you know that you are going to be printing in that orientation its often best if the design allows to do a hybrid chamfer/Fillet.
So you start off at a 45 degree when its at the bed level, and then you transition to the curve when its a bit further up and the angle is not as steep.  Get it right and the bottom will require zero support at all and will still look good and feel ok when holding.

Essentially as you have a defined Z gap between the support interface and the part (often in the 0.2-0.25mm range depending on your settings) and that the layer height is also generally 0.2mm then you cant fit support under layers until they are further away than 0.4mm above the bed realistically.  Even then you also have to take into account the support/part xy separation settings too so in practice its actually a few more layers higher than that.

RE: Unable to Remove Support

That makes sense, thank you again for sharing your knowledge with a newbie :).  I'll try that, make a bevel that goes, 3-4 layers up, then apply the fillet.  This is starting to make sense why my fillet usually has some very distinct "threads" that aren't really in-line with the other layers, causing a "roughness" to the fillet.

Can't thank you enough!

Kindest regards

RE: Unable to Remove Support

For something like this I probably would just go with straight chamfers around the edges but the chamfer/filler method is certainly very good. 

I also hardly ever use supports everywhere. Neophyl showed you how to use support enforcers instead, which is—usually—the better approach. But you can use Supports Everywhere to check your chamfer/fillet design, to see at what point PS thinks no supports are required anymore.

RE: Unable to Remove Support

I foolishly applied the fillet after extruding the 3d model so a lot of my geometry is based off of the fillet, ugh.  I'm working through all of that currently and will try both, just the chamfer and chamfer/fillet, just to see how it feels.

I did try to print 2 cases at the same time and ran into another issue, seems like a bed leveling, possibly.  I'll create another thread for that one.

Thanks again for all the help guiding me through this process, it's accelerated my learning for sure.

Kindest regards.

RE: Unable to Remove Support

I changed my model to have a 1.5mm chamfer and then, at the end of the chamfer, I added a 2.5mm fillet.  Below is a picture of the slicer output.  The left one is my original model with just a filet, the one on the right is the new chamfer/filet combination.  I can see now the large overhang layer on the left one (blue layer), I think that is where my "roughness" was coming from.

I haven't printed the new one yet but just wanted to verify I was on the correct path.

Thanks again for all the help.

Kindest regards

RE: Unable to Remove Support

Yep, that’s looking better.