Many 3D printed designs require some sort of support during the build process. For extruded designs, the material that supports the design is either a soluble or easily removable material or the same materials as the printed part, just printed densely enough to provide support but easy to remove.
Often when printing supports, the outside perimeters and the infill settings were insufficient, creating a weak, thin part. Or, the support structures were too dense without enough separation for easy removal.
A common challenge is thin wall parts. To properly support walls, consider the actual wall thickness of the model when setting perimeters.
Using separation layers in the support process settings can eliminate damage often caused by support structure removal. Additionally, adding one or two dense support layers can increase the quality of the surface finish of the printed part.
Corrective action typically involves making a few thin wall adjustments. Such as increase the number of outside perimeters to match the intended wall width, or increase the infill percentage to create a more solid thin part.
To correct for the structure, designers can use two dense support layers, with 55% density, or use one upper and one lower separation layer to aid in the removal of support structures.
A number of additive vendors offer software that will aid in suggesting the best support options. For example, Gap Fill settings within Simplify3D provide assistance when dealing with thin wall models.