Improving Curved Surfaces | Design for Mass Production 3D Printing

Curved surface finishes on 3D printed parts can often be challenging, especially with the appearance of layer lines as the part moves up the curve. In this video, we delve deep into the details of why these layer lines appear more distinct, especially on the top of curved surfaces. We'll guide you through multiple solutions that will help you improve the appearance of your parts. Whether you're aiming for a smoother finish or seeking innovative ways to enhance aesthetics, these design tips will open up new possibilities for your 3D printed parts.

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00:00 What Causes "Stair Stepping" on Round Prints?
00:56 Increasing Print Resolution to Improve Surface Finish
02:04 Print Vertically for Consistent Surface Finish
02:42 Use Angles and Flat Edges When Possible
03:48 Pixelated Parts Can Offer a Unique Aesthetic
04:52 Utilize Textures to Blend Layer Lines

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Produced by Slant Media

[Litl_Skitl]

Suprised they didn't mention adaptive layers, that way you can have 0.3mm layers and transition to 0.1mm as the slope decreases. Same goes for the trapezoid shape.

[daves.software]

Another solution is variable layer heights. Use larger layer heights and only decrease when the horizontal stepover between the layers exceeds a certain size (down to a certain minimum layer height). This minimizes the amount of time spent printing at very low layer height, so the print times aren't increase as much, and you still get much better surface finish.

Autodesk did something similar for their ember 3d printer.


Edit: Added a clarifying statement so that people don't think I'm there one who implemented it.

[TitanDAZ]

Not sure if you're aware, but there are variable layer heights in almost all is not all slicers now. It allows you to set really thick layer heights for vertical surfaces while creating a gradient down to a finer say 0.05mm layer height for those rounded cases.

[KeithOlson]

Another option is 'non-planar printing'. In this case, an app would warp the top surface to make it flat, the warped model is sliced, then the app unwarps it, resulting in extruder moves in 3 dimensions per layer--rather than the standard 2--and the result is a smoothly curved top. (Obviously, there are limitations to this method, but it works fantastically well within them.)

[Crokto]

if he says to just print it on the side im gonna scream.

e: lmao

[geezerreviews]

Hey I just want to give you a big thank you! I enjoy your videos so much and they help us little guys print better parts. I know you could keep this information to yourself and say its trade secrets etc. but you don't. I feel you truly care about the 3d printing industry and want to see everyone be as successful as you, and put out quality parts. Kudos to you and your team. Thank you again for all your awesome videos!

[paultouya]

“How to prevent stepping”… “make a different part” 😑

Why no mention of variable layer heights?

[kelvin]

Embrace the layer line, the layer line is art

[roysigurdkarlsbakk]

Well - adaptive layer height works, which works well in PrusaSlicer and friends. Also, Fuzzy skin, also in PrusaSlicer etc, does what you mentioned lastly, only without any work for the 3d model.

[zachsss]

Im a new printer here, and this was a very well made video

[TheAndyroo]

In prusaslicer I add a height range modifier and choose a range that covers the curve and choose to halve the layer height for that section. You can then click the adaptive layer height icon in the toolbar and choose "smooth" to blend the transition area. I also add a low level amount of fuzzy skin - 0.03mm depth, 0.06mm distance to try hide the layer lines more.

[alexandrosmarinos]

You could try high resolution just on the top portion, getting most of the value for a fraction of the delay. I suppose a slicer could implement gradual layer height reduction to make it even nicer, but even without that, you can improve things a lot for a minor delay.

[faizaanmirza]

You could just print the part on its side.
The other examples/suggestions are to change the geometry in its entirety which is not printing curved surfaces anymore. The scope for improvement here is null. How do you improve something but not doing it?

Print in ABS and acetone vapour exposure. That is the ideal solution for mass producing curved surfaces.

[trulsdirio]

If you are trying to make tens of thousands just use injection moulding. Like seriously, 3D printing does scale pretty poorly. I understand it is appealing as you can gradually increase capacity as you go by adding more printers, but there is a limit to when it makes sense.

[lucianoag]

Adaptive layer height. It would be great if you could use a formula to determine h as a function of z
For example h = min(max(0.1, 0.4 sqrt (R^2/z^2-1), 0.3).
That would give you the necessary height to have a constant step of 0.4 mm but having 0.3 and 0.1 as upper and lower limits.

[acekozmo]

At 2:06 was there a reason to put a chamfer on it even though that profile was flat already? (not sarcastic)

[CurtWelch]

I love using the stairstep approach to design. I will often go all the way down to .3mm steps, and then the part will perfectly match my designed shape and eliminate the layer effect that happens when you design and try to print curved parts!

[DerSolinski]

Cura has dynamic layer height exactly for this reason.
While I find the stock settings somewhat lacking you can customize them to something that fits your need.

[TheGeneral]

Maybe I'm the odd one out, but I really don't mind the sort of stair-stepping appearance of layer lines towards the top of a curved surface like that. That said, I understand there's a lot of considerations that need to be made if you're producing and selling parts like this that I as a hobbyist don't really need to consider. I still really appreciate and enjoy your videos, and have incorporated some of your tips into my own designs already.

[AntiKipKay]

Using the adaptive layer function of the slicer is good too. It only reduces the layer height over fine areas like the top. Saves on printing time.