Scientists at the Department of Energy’s Oak Ridge National Laboratory have created the first additive manufacturing slicing computer application that both accelerates and simplifies the digital conversion of precise, large-format 3D parts in an industrial production environment.
The technology, known as Slicer 2, is set to broaden the applications of 3D printing for larger objects made from metallic and composite materials. This includes the possibility of creating structures as large as houses, as well as land and aquatic vehicles, and aerospace components such as parts for reusable space vehicles.
Slicing software transforms a computer-aided design (CAD) digital model into a sequence of two-dimensional layers called slices. It determines print parameters for each slice, like the path and speed of the printhead, and encodes this information in a numerically controlled language. This computer file provides the 3D printer with instructions to produce an accurate 3D version of the model.
“The quality of a 3D-printed object depends on the precision and complexity of the toolpaths that direct the machine’s movements,” explained ORNL researcher Alex Roschli. “ORNL Slicer 2 software interfaces directly with various 3D printers to create a unified platform and uses sensors to enhance print accuracy.”
Researchers developed ORNL Slicer 2 with over 500 settings to manage the internal structure, shape, temperature, and other parameters of individual parts, layers, or regions. It also integrates with simulation software to display complex heat and stress interactions during the additive manufacturing process. The software supports various additive manufacturing systems, including pellet and filament thermoplastics, thermosets, concrete, laser wire welding, MIG welding, and blown-powder directed-energy deposition.
“This connectivity enhances machine commands, improving the reliability and consistency of the additive manufacturing process,” noted Roschli. “The software enables manufacturers to produce large factory parts with fewer machines and at a lower cost compared to traditional machining methods.”
ORNL Slicer 2 is an open-source program available on GitHub and is utilized by over 50 equipment manufacturers, industrial end users, and universities.
