Daniel’s Large Assignment 4: GCODE

My Process and How My Code Generates My Three Shapes

My design process began with exploring the Extruder Turtle Library, which provides functions for generating G-code for 3D printing. I started by implementing the examples presented in class and then proceeded to experiment with different shapes that caught my interest.

During this exploratory phase, I created numerous designs, but I encountered significant challenges. Many of my initial attempts resulted in poorly printed artifacts or outright failures. In total, I would estimate around 40 failed or subpar prints during my experimentation. This struggle stemmed from a combination of issues, including difficulties in generating effective G-code and ensuring compatibility with my specific printer model, the Ender V3 S3.

I focused on developing three unique shapes that I believe cannot be easily produced by traditional slicing software. These shapes not only showcase the capabilities of the Extruder Turtle Library but also highlight the importance of iterative design. My final forms emerged from a rigorous process of trial and error, allowing me to refine my G-code and adapt my designs based on the results of my previous prints.

Overcoming Slicer Limitations: A Case for Custom G-code

The shapes I created for this assignment cannot be generated by traditional slicing software due to their complex geometries and non-standard printing requirements. One of the designs incorporates freestanding lines of filament (Droopy Sun), which require precise control over the extruder’s movement to ensure stability and adherence without additional support structures—something that slicers typically struggle to accommodate. Furthermore, another shape features non-planar movements of the nozzle (Sine_Cylinder), allowing for intricate layering and variations in filament quality as the extruder moves above the print surface. This complexity in toolpath—where the Z-axis continually shifts for each layer—exceeds the capabilities of standard slicing algorithms, which primarily focus on planar layer-by-layer generation.

1. Lattice/Chain Like Structure

Source: How 3D Printed Lattice Structures Improve Mechanical Properties – 3D Printing

For the first design, I aimed to create a lattice or chain-like structure, inspired by 3D-printed lattice forms commonly used to improve mechanical properties in engineering. Although I originally planned to apply the lattice pattern to the entire hexagon, I could only focus on just the perimeter. My initial expectation was that this would result in gaps, similar to a chain-link fence, but the final print came out fully connected. Surprisingly, this gave the structure significant strength, exceeding what I had anticipated while still maintaining the open, lightweight feel of the design.

2. The Droopy Sun

The second form, which I call the “Droopy Sun,” incorporates freestanding lines of filament that were intentionally drooped to form a wavy, suspended pattern. Traditional slicers struggle with freestanding elements like these, but through custom G-code manipulation, I was able to control the movement of the extruder to create this unsupported structure. The challenge was balancing the extruder speed and the height of the nozzle to avoid breakage while maintaining the intended design. While the final print turned out delicate, it successfully demonstrates the limitations of slicing software when handling complex, non-planar geometries.

3. Sine Cylinder

For my third design, I implemented a sine curve integrated into a circular pattern using the Extruder Turtle Library. This design showcases non-planar Z-axis movement by varying the height of the extruder according to the sine wave function. The extruder moves in a circular path while simultaneously oscillating vertically based on the sine values, creating an intricate wave-like surface. Specifically, as the extruder completes each revolution, the Z-coordinate rises and falls, generating positive sine variations that enhance the visual complexity of the print. This technique not only allows for dynamic layering but also results in an engaging texture, as the filament’s position varies with the sine wave, highlighting the capabilities of custom G-code to achieve intricate geometries that traditional slicing software cannot produce. I began by first printing a square bed for the shape, then printed 20 circles and 180 sine wave curves.

Final Prints

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