Scaling additive manufacturing to large component dimensions places high demands on software, process control, and data integration. The Oak Ridge National Laboratory has therefore introduced a new version of its slicing software. ORNL Slicer 2 is designed to accelerate the preparation and optimization of large-format 3D prints and is aimed at industrial applications using material extrusion and Directed Energy Deposition.
Conventional slicers translate CAD models into two-dimensional layers and calculate toolpaths and process parameters from them. Slicer 2 goes beyond this by integrating different printing systems and sensors into a shared software environment. The goal is an end-to-end process chain that allows adjustments to be made during production.
“The latest release of Slicer 2 includes many significant updates, improvements, and bug fixes,” said Alex Roschli, a researcher in ORNL’s System Automation and Monitoring group. “One major change is a new system that helps automate the creation of files that can be easily distributed to our users.”
A key technical focus is improved cross-section visualization. More precise representations of tool movement at different depths enable more accurate geometry planning, which is particularly relevant for large-volume structures with varying wall thicknesses. In addition, Slicer 2 allows the simulation of different bead widths prior to actual printing. Although bead width is primarily determined by nozzle diameter, it can be deliberately varied during the process to realize more complex shapes.
The software links these dynamic adjustments with calibration values and sensor data from the machine. This enables printing systems to respond to deviations in real time. According to ORNL, this approach helps reduce material consumption, improve part quality, and shorten lead times. Users in the aerospace, automotive, and defense sectors are already using Slicer 2 for tooling, functional components, and prototypes.
ORNL is operated by UT-Battelle on behalf of the U.S. Department of Energy. The continued development of Slicer 2 underscores the laboratory’s focus on software-enabled process stability as a prerequisite for industrial additive manufacturing at large scale.
Subscribe to our Newsletter
3DPresso is a weekly newsletter that links to the most exciting global stories from the 3D printing and additive manufacturing industry.
