Influence of Slicing Strategy on FFF Parts Dimensional Deviations

Abstract

Dimensional accuracy is critical in industrial applications and can limit the use of Fused Filament Fabrication FFF. The printing steps required in material extrusion: pre-processing, processing, and post-processing influence dimensions. While processing and post-processing steps lead to inaccuracies due to machine limitations, dimensional errors from the pre-processing step are motivated by inadequate representations and mathematical approaches. This work studies if the slicing approach can contribute to dimensional deviations. It is considered a pyramid sample with four different wall angles to check this hypothesis. Next, its CAD model is sliced using three approaches: inclusive, middle, and exclusive. The resulting gcodes were compared against the theoretical pyramid sections to quantify deviations. It is worth mentioning that each slicing approach shows a different deviation curve along the printing direction and the wall angle. These results highlight the slicing strategy as a potential source of dimensional inaccuracies. Finally, three sample cases (one for each slicing strategy) are printed, measured, and compared using a 3D scanner and conventional measurements to support the numerical examples.