Optimum part filling via layer-wise variation of raster angle in fused filament fabrication

In Fused Filament Fabrication (FFF), the raster angle stands out as a critical parameter that can significantly impact the material infill within each layer. Current commercial FFF software typically employs fixed raster angles to generate toolpaths, which occasionally result in gaps between contour and infill pathways. Such gaps can compromise the quality of the printed part during fabrication. Introducing variations in the raster angle based on the geometry of each layer could potentially mitigate the formation of these gaps and enhance the overall filling of the part. Hence, this study introduces a novel approach to part fabrication that adjusts raster angles according to layer geometry. This approach has been evaluated across various complex models with diverse cross-sectional geometries along the Z-axis. The results indicate a substantial percentage reduction in total unfilled space, with a reduction of approximately 99.96%, consistent with similar findings reported in the case studies of the present work. Furthermore, a user-friendly graphical interface has been developed to enhance the accessibility and usability of the proposed approach.