Bambu Studio slices inner wall in mid-air on overhang layer

[JonRaymond]

The floating hole slicing problem has been around for a long time.

@JonRaymond

So the issue with an unsupported vertical hole is that the printer really struggles trying to bridge from a supported section (the wall) to one that is in mid air (The yet to be printed hole). There is nothing for the bridge to connect to and the wall of the hole to build on.

The trick here is to “build” a surface in CAD that the printer can bridge correctly on either side (or in several orientations depending on the hole size) that the hole wall can then be printed up from.

A good video describing the issue and different solutions.

How to 3D Print bores without supports (Fusion 360 Masterclass)