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Planar and nonplanar slicing algorithms for fused deposition modeling technology: a critical review

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Abstract

Fused deposition modeling (FDM) is one of the most popular and ubiquitous additive manufacturing methods, which uses a layering procedure to build 3D models layers-upon-layers. Since the layers are the constituents of the resulted 3D part, the layering process can directly affect the part’s surface finish and mechanical properties, which are the two major drawbacks in FDM. To this end, investigating different layering/slicing algorithms can deepen the understanding of the challenges and gaps in FDM, which will help improve the quality of the 3D printed parts. In this review, slicing algorithms developed for FDM technology are categorized into two main groups: planar and nonplanar. While planar algorithms generate flat layers, nonplanar algorithms provide curved and out-of-plane layers, increasing build speed, eliminating support structures, smoothening the outer surface, and enhancing mechanical properties. Planar algorithms are subdivided into single-axis and multi-axis algorithms. Single-axis printing confines the build direction along the perpendicular axis of the build platform, while multi-axis printing can change the build direction for different layers. Conventional Cartesian printers can achieve single-axis planar printing and are the dominant approach in commercial FDM printers. Upgraded hardware and complicated calculations are needed to enable the printer to deploy multi-axis planar and nonplanar printing capability, which are the downsides of these advanced methods. This review broadly discusses the impact of the slicing algorithm on the surface quality, build time, support structure, and mechanical properties of 3D printed parts. Current challenges and prospective solutions are presented.

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This research was supported by the Natural Sciences and Engineering Research Council of Canada – Discovery Grants program (NSERC-DG).

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  1. Department of Mechanical Engineering, Faculty of Engineering and Architectural Sciences, Ryerson University, 350 Victoria Street, Toronto, ON, M5B 2K3, Canada

    Pooyan Nayyeri, Kourosh Zareinia & Habiba Bougherara

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Pooyan Nayyeri: Conceptualization; investigation; writing, original draft; writing, review and editing. Kourosh Zareinia: Writing, review and editing. Habiba Bougherara: Supervising; writing, review and editing; funding acquisition.

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Nayyeri, P., Zareinia, K. & Bougherara, H. Planar and nonplanar slicing algorithms for fused deposition modeling technology: a critical review. Int J Adv Manuf Technol 119, 2785–2810 (2022). https://doi.org/10.1007/s00170-021-08347-x

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