Curved Layer Adaptive Slicing (CLAS) for fused deposition modelling

Abstract

Purpose – This paper aims to develop a new slicing method for fused deposition modelling (FDM), the curved layer adaptive slicing (CLAS), combining adaptive flat layer and curved layer slicing together. Design/methodology/approach – This research begins with a review of current curved layer and adaptive slicing algorithms employed in the FDM and further improvement of the same, where possible. The two approaches are then integrated to develop the adaptive curved layer slicing based on the three-plane intersection method for curved layer offsetting and consideration of facet angles together with the residual heights for adaptive slicing. A practical implementation showed that curved layer adaptive layers respond in similar lines to the flat layer counterparts in terms of the mechanical behaviour of FDM parts. Findings – CLAS is effective in capturing sharply varying surface profiles and other finer part details, apart from imparting fibre continuity. Three-point bending tests on light curved parts made of curved layers of varying thicknesses prove thicker curved layers to result in better mechanical properties. Research limitations/implications – The algorithms developed in this research can handle relatively simple shapes to develop adaptive curved slices, but further developments are necessary for more complex shapes. The test facilities also need further improvements, to be able to programmatically implement adaptive curved layer slicing over a wide range of thicknesses. Practical implications – When fully developed and implemented, CLAS will allow for better FDM part construction with lesser build times. Originality/value – This research fills a gap in terms of integrating both curved layer and adaptive slicing techniques to better slice and build a part of given geometry using FDM.