A recently published study presents an innovative technique for improving the surface quality of FDM 3D prints: non-planar ironing. This method promises to simplify the post-processing of 3D-printed objects and at the same time increase the surface quality.
With conventional ironing, which is available as an option in many slicers, the print head moves over the top layer with a minimal plastic feed in order to smooth out any unevenness. Non-planar ironing goes one step further. It manipulates the layer height in real time to create precise curvatures.
This technique is based on the concept of non-planar printing, which normally requires rotation of the print bed. The new method avoids this need by focussing on the final layers of the printed object.
The researchers have developed a Python script that modifies the G-code of the top layer after the slicing process. Initial test results show an impressive improvement in surface quality. However, comprehensive testing on more complex geometries is still pending.
A major advantage of this method is its accessibility. It only requires a standard 3D printer, a modified version of Slic3r and the aforementioned Python script. This enables experienced users to test and implement the technology with relatively little effort.
The authors of the study are also involved in the development of Curvislicer, a slicer that supports non-planar printing. This suggests that the new ironing method could potentially be integrated into future versions of this tool.
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