Custom Non-planar 3D printing Slicer

This ongoing research initiative investigates advanced computational toolpath generation for additive manufacturing, specifically targeting the geometric and structural limitations of conventional 2.5D planar slicing.

Standard Fused Deposition Modeling (FDM) slices 3D CAD models into flat horizontal layers, creating noticeable staircase artifacts and significant structural weaknesses along the Z-axis (inter-layer delamination). By developing a custom non-planar slicing engine in Python and Grasshopper/Compas, toolpaths conform directly to curved surfaces and principal stress lines.

The custom slicer coordinates non-planar extruder velocities, dynamic nozzle clearance algorithms to prevent collision, and variable layer heights. The result is continuous fiber-aligned filament deposition that dramatically enhances structural strength, surface smoothness, and geometric freedom without requiring sacrificial support structures.