Slic3r Post-Processing Script For Non-Planar Layer FDM (Perl)

Warps boring, planar G-code from Slic3r (or any other slicer) into wavy shapes. This repository accompanies the corresponding Hackaday article.

Features

• wavyness-ramps, -in and -out points
• extrusion compensation
• fully configurable through start- and end-gcode, no script modifications required
• configurable displacement
• custom displacement function through Perl expression

Printing parameters and default values

• set via ; some_parameter = 2 in start or end G-code (or anywhere else)
• available via $parameters{"some_parameter"} in the script
• script parameters:
  • ; wave_amplitude = 2.0 [mm] the maximum amplitude of the wavyness
  • ; wave_length = 20.0 [mm] the wave length in xy direction of the waves
  • ; wave_length_2 = 200.0 [mm] an additional wave length parameter, currently only used for testing the wing function
  • ; wave_in = 0.4 [mm] the z-position where it starts getting wavy, should be somewhere above the first layer
  • ; wave_out = 30.0[mm] the z-position where it stops beeing wavy
  • ; wave_ramp = 10.0 [mm] the length of the transition between not wavy at all and maximum wavyness
  • ; wave_max_segment_length = 1.0 # [mm] max. length of the wave segments, smaller values give a better approximation
  • ; wave_digits = 4 [1] accuracy of output G-code
  • ; wave_function = wave [String/Perl] wave function, can be "wave", "wing", or any Perl expression (i.e. abs($x-$paramters{"bed_center_x"})), which may make use of $x or $parameters{"bed_center_x"} as well as any other user defined parameter

How to use

• Have Perl installed and path variables set (Windows users: Strawberry Perl, Linux and OSX: you already have Perl)
• Make sure the Math:Round module is installed (Linux and OSX cpan Math::Round / Windows either Start Menu -> All Apps -> Strawberry Perl -> CPAN Client or ppm install Math:Round). If you happen to use Active Perl, you'll probably need a Business License for this module.
• Set Slic3r -> Preferences -> Mode to Expert
• Add ; start of print to the beginning of your G-code (ideally at the end of your start G-code)
• Add ; end of print to the end of your G-code (ideally at the beginning of your end G-code)
• Add parameters (see above) to your start G-code as desired
• Add absolute path to the script in Slic3r -> Print Settings -> Output options -> Post-processing scripts (no /~ allowed)
• Make sure Slic3r -> Printer Settings -> General -> Advanced -> Use relative E distances is checked
• Make sure to UNCHECK Slic3r -> Print Settings -> Layers and perimeters -> Vertical shells -> Spiral vase.
• Make sure all XYZ moves between ; start of print and ; end of print are in absolute mode
• Optional: Check Slic3r -> Print Settings -> Output options -> Output file -> Verbose G-code
• Make sure the script file is executable by chmod 755 non-planar-layer-fdm.pl
• Slice (& Warp)!

Examples

The example folder contains additional examples with instructions. Here are a few impressions:

Curved surfaces

Structured surfaces

Gradually displaced cube

Wing

FAQ

Why?

• Strength
  • The wave displacement transforms tensile forces (=weakness of FDM) between printed layers into shearing forces (=strength of FDM)
  • More uniform resistance of tensile stress due to varying layer orientation
• Smooth, curved surfaces, i.e. for
  • aerodynamic applications (i.e. models of aircrafts, cars)
  • ergonomic or haptic elements (i.e. buttons, keypads)
• Structured surfaces (see Examples)
  • haptic elements
• Design & aesthetics
• Artistic purposes
• Fun

Doesn't this mess up my parts?

• Yes, totally. If you want straight parts afterwards you need to pre-warp them.
• I'm currently experimenting with ImplicitCAD for pre-warped parts.
• A pre-warping script is in the works.

Why u no use CPAN modules, i.e. Gcode::Interpreter

• They're just not made for this kind of experiments.

Troubleshooting

Why doesn't it work

• Are you running Windows 8.1 and might be experiencing a Slic3r bug?
• Are you using the Slic3r -> Print Settings -> Layers and perimeters -> Vertical shells -> Spiral vase? This option is currently incompatible with the script.
• Did you check Slic3r -> Printer Settings -> General -> Advanced -> Use relative E distances?
• Did you make sure the script file is executable by chmod 755 non-planar-layer-fdm.pl?

Disclaimer / License

This is a work in progress. Any suggestions are heavily welcome. All scripts in this repository are licensed under the GNU Affero General Public License, version 3. Created by Moritz Walter 2016.