Adaptive Layering Algorithm Based on Optimal Volumetric Deviation Ratio for Printing Complex Models with Significant Differences in Interlayer Area

This article aims to construct theoretical model and program of a new adaptive layering algorithm (ADR) by setting optimal volumetric deviation thresholding and matching printing speed. It can optimize both printing efficiency and dimensional accuracy simultaneously, which the traditional ADRs based on area deviation and volumetric deviation metrics have not taken into account. First, the optimal volumetric deviation ratio (OVDR) model was studied considering the overall volumetric deviation and printing time of the model. Second, a process for obtaining the OVDR of the model and an ADR process with the OVDR as the threshold was constructed. For bunny model, the overall volumetric deviation is reduced by 15.46% when the printing time is the same as the area deviation ratio-based ADR. When the overall volumetric deviation is the same as the volumetric error (VE)-based ADR, the printing time is reduced by 13.96%. Through data and thermal coupling analysis, the effects of layer number, volumetric deviation ratio, printing speed, and temperature on extrusion deformation were investigated finally. The article shows this new ADR and the optimal speed selection for continuous printing layers, where the volumetric deviation ratio is below the threshold value of volumetric deviation ratio, are effect in improving both printing efficiency and molding accuracy. For bunny model, the printing time has increased by about 4% and the surface roughness has decreased by 47.5% at the optimal printing speed. These conclusive results support enunciating recommendations for use in the industrial environment. This article fulfills the demand to improve both printing efficiency and molding accuracy by investigating a novel ADR and optimal printing speeds. It demonstrates better adaptability for printing complex models with significant differences in interlayer area.