Getting Smoother Curves: Understanding Non-Planar 3D Printing

Image via: Pexels by Jakub Zerdzicki

Visible layer lines commonly known as stair-step effect can be an issue on your curved or sloped surfaces 3D printed parts. This common challenge in additive manufacturing affects both the look and sometimes the strength of your components. Non planar 3D printing is a developing technique that directly addresses this problem by changing how layers are applied.

This article will help you understand the following about non planar 3D printing:

● What it means and how it works.

● How it can improve part quality.

● The technical needs, like special G-code 3D printing and 3D print axis control.

● The evolving landscape of 3D printing

A 3D printed curved object showing visible layer steps or the stair step effect.

What is Non-Planar 3D Printing? Going Beyond Flat Layers.

Traditional 3D printing builds objects by stacking many flat, horizontal layers. The print head typically moves along the X and Y 3D printer axis to create a layer, then the 3D printer z axis shifts up for the next one. This method is well-established.

Non-planar 3D printing takes a different path. Instead of only flat layers, the print nozzle follows the actual curved contours of an object's surface. This requires the 3D printer axis – X, Y, and Z  to move simultaneously in a coordinated, three-dimensional way. Some advanced setups might even use 4-axis or 5-axis systems to give the print head more freedom to tilt and move along these complex paths.

How Non-Planar Printing Improves Part Quality

The main reason to consider non planar methods is to achieve better results on parts with curved surfaces:

● Smoother finishes

By depositing material along the curve, non planar printing can greatly reduce the stair-step effect. This means a smoother surface right from the printer, potentially reducing post-processing needs.

● Better strength profile

Layer adhesion is a common weakness in planar 3D printing, especially along the Z axis. Non-planar printing’s continuous, curved layering improves mechanical properties by distributing stresses more evenly, resulting in parts that are stronger and more reliable in real-world applications.

● Reduced supports material and waste

Because the printer follows the contours of the object, it can naturally support overhangs and complex features without relying heavily on additional support structures. This not only saves material costs but also reduces print time and simplifies cleanup.

● Faster production with multi-axis precision

Incorporating a 4 axis or more advanced multi-axis system allows simultaneous movement across multiple planes, enabling faster print speeds and more intricate designs. This capability is especially valuable for industrial applications requiring precision and efficiency.

Key Technical Requirements for Non-Planar Printing

Multi-axis G-code toolpaths necessary for guiding a non-planar 3D printing process

Making non planar prints successfully is more complex than standard printing, here are the requirements:

● Specialized slicing and G-code - Standard slicers create instructions for flat layers. Non planar 3D printing needs advanced software that can generate complex G-code 3D printing toolpaths. These paths must precisely guide the multi-3D printing axis movements and adjust material flow for curved deposition, all while avoiding collisions.

● Precise machine movement and calibration - The printer must be very accurate. You need to precisely calibrate 3D printer mechanics to ensure the print head can follow these intricate curved paths exactly. Any small error in 3D print axis movement can affect the outcome.

● Printer hardware - Sometimes, specialized hardware is needed. This might include longer nozzles for better clearance around the print head or even multi-axis robotic arms for full 4-axis or 5-axis movement.

The Evolving Landscape of 3D Printing

The journey into non planar 3D printing shows real promise for tackling some of the common limitations in additive manufacturing. However, realizing these benefits consistently requires overcoming notable technical challenges.

As non planar technology continues to mature, it highlights the broader trend in advanced manufacturing towards more sophisticated control and greater design freedom. Understanding these emerging possibilities will help you think differently about how parts can be made, pushing beyond the constraints of the conventional 3D printer z axis step-by-step build.

Contact our team to discuss your project's unique requirements and our experts are ready to evaluate your needs and offer tailored solutions .