So, I made a little bit of progress on support material settings. After asking Hyrel, they suggested that change the Slic3r settings so that the interface layers (the layers that adhere the support to the part) are printed by a fantom head (i.e. aren’t printed at all). In theory this should work great! Less adhesion to the part would mean that the supports should come off easier. They definitely came off easier, but the difference was marginal. I still broke the bottom half of the kylo ren mask trying to remove the support material, so the settings aren’t quite there yet.
I might try playing with pattern spacing next (i.e. distance between support material pillars / interface layers)! Hopefully that will help a little bit. Stay tuned!
John (aka the Mad Printer)
The Mad Printer 