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.