Erodible support structure for additively manufactured article and process therefor

A method for constructing an additive manufactured article with an overhanging geometry and an erodible support for the overhanging geometry, comprising:

• computing a length of the overhanging geometry defined as a structure that extends from an inner surface of an additively manufactured article, wherein the overhanging geometry extends from the inner surface at an angle between a build plane for the method and the overhanging geometry, wherein the angle is less than a critical angle for the additive process, and wherein the critical angle is between 35 and 75 degrees;
• determining a multiple of points along the overhanging geometry at a predetermined spacing;
• determining an outside point and an inside point of the multiple of points, wherein the inside point is a point of the multiple of points that is closest to the inner surface, and the outside point is a point of the multiple of points that is furthest away from the inner surface;
• determining an anchor point on the inner surface such that a vector from the outside point to the anchor point is at an angle with respect to the build plane that is greater than the critical angle of the additive process;
• associating the anchor point to the overhanging geometry points to additively form ligament segments between the anchor point and the overhanging geometry points;
• thickening the ligament segments to form the erodible support;
• and
• additively manufacturing the overhanging geometry from the inner surface and supported by the erodible support, the erodible support being erodible during operation of the additively manufactured article.