Optimal Strategies for Filament Orientation in Non-Planar 3D Printing

The structural integrity and surface quality of parts produced using traditional fused deposition modeling depend on factors such as layer height, filament and build orientation, print speed, nozzle temperature, and, crucially for this study, both planar and non-planar slicing. Recent research on non-planar slicing techniques has shown significant improvements in surface smoothness and mechanical properties. Key approaches include non-planar slicing for 3-axis printers, adaptive slicing to optimize material placement in critical areas, and post-processing. However, current studies lack a comprehensive method for parameterizing filament direction across both planar and non-planar layers. This work presents an approach to generate optimal trajectories for planar and non-planar layers using contours derived from level set functions. The methodology demonstrates the advantages of non-planar printing, particularly with a filament orientation of 30° for inclined surfaces, ensuring better surface quality, uniformity, and structural integrity. This emphasizes the importance of trajectory planning and filament orientation in achieving high-quality prints on inclined geometries. This research highlights the necessity of a methodology that tailors filament paths based on the load-bearing requirements of each part, demonstrating its potential to enhance surface quality and structural performance, and further the advancement of the 3D printing industry. © 2024 by the authors.