FDM systems and local adaptive slicing

Abstract

Fabrication times for layered manufacturing systems can be significantly reduced by continuously maximizing the build layer thickness, within the bounds of the system's fabrication capabilities and the surface deviation tolerance derived from the part surface geometry. This paper describes how parts and features within a build volume can be adaptively sliced independently of each other such that each is fabricated with distinct build layer thicknesses. This enables significant reduction in fabrication times relative to conventional adaptive build layer thickness techniques. The new approach has been implemented on a FDM 1600 rapid prototyping system, together with a revised system calibration to ensure smooth surface transitions between dissimilar build layer thicknesses.