| Abstract Scope |
Support-free fabrication on conventional 3-axis FDM systems remains challenging because fixed nozzle orientation limits feasible overhang deposition. The S3/S4 non-planar slicing pipelines enable support-free additive manufacturing by deforming a model into a printable geometry, slicing it in the deformed state, and mapping the toolpaths back to the original shape. However, because the original framework was developed for multi-axis systems, it cannot be applied directly to conventional 3-axis FDM. This work adapts the pipeline for Cartesian 3-axis printing. Tetrahedralization, volumetric deformation, and slicing in deformed space were carried over from S3/S4 with minor modifications, while inverse toolpath reconstruction required major development, and the overhang-handling strategy was reformulated through constrained rotation-field propagation and distance-dependent rotation limits compatible with 3-axis manufacturability. Results show that the adapted pipeline can generate printable non-planar toolpaths for three benchmark geometries, but breaks down in overhang regions bounded by multiple supported edges, demonstrating both its promise and limitations. |