Fused deposition modeling (FDM) is one of the fastest growing three-dimensional (3D) technology and the extensively employed additive manufacturing process for producing prototypes and functional components in numerous engineering applications. Its widespread compliance can be attributed to its ability of building parts with complex geometrical shapes in reasonable time period. However, the fundamental drawback with FDM is the manufacturing of overhang structures. Therefore, the support structures are imperative and are most often utilized for 3D printing of overhanging surfaces to avert any failure especially when optimum orientation is ineffective. Certainly, this technique of providing support structures is not always adequate and several challenges can be associated with them, such as low printing efficiency, material wastage, higher time and material needs, post-processing requirements, likelihood of part damage, etc. As a result, this work carries out a study to determine the influence of different model interior fill and support structures on building time, material utilization in part as well as support structures, and overhang surface deformation. Additionally, this work has analyzed the deformation profile of the overhang surfaces. The primary objective in this study is the selection of appropriate setting or the strategy for efficacious and economical construction of overhang surfaces in FDM.