Method for supporting three dimensional (3D) printed features

A method for forming a three dimensional printed product, comprising:

• forming a sacrificial support structure using a method comprising:
• ejecting only a first drop of a print material sequentially at each of a plurality of pillar locations from a print head;
• curing each first drop;
• then
• ejecting only a second drop of the print material sequentially onto the first drop at each of the plurality of pillar locations from the print head after curing each first drop;
• curing each second drop;
• then
• ejecting additional drops of the print material sequentially at two or more of the pillar locations to form a plurality of pillars after curing each second drop;
• wherein the sacrificial support structure comprises:
• a base comprising a first plurality of levels, wherein each level of the first plurality of levels comprises at least two drops of the print material, wherein the at least two drops physically contact each other;
• and
• a breakaway comprising a second plurality of levels, wherein each level of the second plurality of levels comprises only one drop of the print material and forms a physically weaker contact point between the first plurality of levels and the three dimensional printed product;
• forming the three dimensional printed product using a method comprising ejecting a plurality of third drops onto a plurality of fourth drops while the plurality of fourth drops are uncured;
• and
• physically separating the sacrificial support structure from the three dimensional printed product via a contact point between the sacrificial support structure and the three dimensional printed product.

A method for forming a three dimensional printed structure, the printed structure comprising a plurality of pillars at a plurality of pillar locations, the method comprising:

• ejecting only a first drop of a print material sequentially at each of the plurality of pillar locations from a print head onto a surface of a substrate to form a first printed layer;
• then ejecting only a second drop of the print material sequentially onto the first drop at each of the plurality of pillar locations from the print head to form a second printed layer on the first printed layer, where each second drop is vertically aligned with one of the first drops;
• then ejecting additional drops of the print material sequentially at two or more of the pillar locations, where each additional drop is vertically aligned with one of the second drops;
• printing a plurality of drops that are laterally offset from the additional drops to form a plurality of lateral supports, wherein each lateral support bridges two adjacent pillars and the plurality of drops do not physically contact the surface of the substrate or any drops below, wherein the three dimensional printed structure comprises a three dimensional printed product and a sacrificial support structure;
• and physically separating one or more of the plurality of pillars from the three dimensional printed product via a contact point between the sacrificial support structure and the three dimensional printed product.