As most people know, Ultimaker 3D printers use Fused Deposition Modeling (or FDM) to create physical objects.
This process involves slicing a digital model into a stack of horizontal layers using slicing software like Ultimaker Cura.
These layers are then printed sequentially to form a physical object.
Quality and Speed
Most slicing software assigns a constant spacing (called layer height) between each layer.
Very fine layer heights produce high-resolution models, but each additional layer increases the printing time. Thicker layer heights print faster – because fewer layers are printed – but the finished model has less detail. These situations force users to choose between optimizing print time or print quality.
What if you could have the best of both worlds – allowing your print layer height to adapt to the object's shape?
Adaptive Layers, a new slicing feature available since Ultimaker Cura 3.2, makes this possible.
Applying Adaptive Layers in Product Development
What does this mean in practice? Poly-Tainer Inc., a plastic bottle manufacturer and decorator, produces containers for health and beauty market products.
To accelerate their 3D CAD design implementation process, they invested in two Ultimaker 3 Extended printers for in-house prototyping.
With 3D printing technology, Poly-Tainer can share accurate concept models with their customers (often major retailers like Target and Walmart)
and eliminate design uncertainties before investing up to $100,000 in mass production molds.
Bottle prototype using the "Fast" slice profile in Ultimaker Cura. Layer thickness consistently maintained at 0.2mm (200micron).
Bottle prototype sliced with Adaptive Layers. Print time reduced by 10%, and more detail given to areas that need it.
The appearance of the final product on the shelf is an important consideration in the sales process. Using adaptive layers, Poly-Tainer can print detailed concept models with improved appearance and quality in less time than models with constant layer heights.
Angled parts of the model have finer steps per layer, and important design elements (such as the threading on the bottle neck) have better detail.
The layer thickness color scheme included in the Ultimaker Cura layer view shows variations in layer thickness. In this example, thicker layers are yellow, and finer layers are blue.
The Ultimaker 3's dual extrusion capability allows for soluble PVA support material, which helps achieve design features such as "bottom raise," an important design element in bottle manufacturing. Compared to constant layer height, using adaptive layers and soluble PVA support can create this concept model faster and with clearly defined decorative bevels. The increased detail also helps with precise multi-color mesh printing during the bottle decoration process.
Bottom raise is an ideal feature for health and beauty product containers. This feature's horizontal cross-section shows the blue support structure. After printing,
the support material can be easily dissolved in tap water.
Precise 3D printed concept models allow Poly-Tainer to order custom decorative tools before production tools create the first product. This saves approximately 4-6 weeks in bringing new designs to market.
How Adaptive Layers Optimize Speed and Detail
Ultimaker Cura's adaptive layers feature analyzes the slope of the model's outer walls. The slicing engine optimizes the layer thickness for each section. Curves are printed with a finer layer analysis rate, while vertical flat areas are printed with thicker layers, shortening print time. The calculation is automatic, and users can specify three parameters: maximum variation, variation step, and layer threshold. Default parameters are often sufficient to provide good results, but testing can further optimize print time for user-specific models while still preserving fine detail.
Free Slicing Software Available
Ultimaker Cura is completely free for users. You can try this feature by loading this sample .STL file into Ultimaker Cura 3.2 or higher.
Access Adaptive Layers settings from Ultimaker Cura's interface by switching to custom mode and searching for "Adaptive Layers" in the search bar. We always love to hear how Ultimaker helps people streamline their business processes. What features do you think are most important for your workflow?
Feel free to share your thoughts in our 3D printing expert community.
Special thanks to Frank Cowles of Poly-Tainer Inc.
Original link:https://ultimaker.com/en/blog/52520-print-detailed-objects-faster-using-adaptive-layers-in-ultimaker-cura