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prusa3d / PrusaSlicer

G-code generator for 3D printers (RepRap, Makerbot, Ultimaker etc.)
https://www.prusa3d.com/prusaslicer/
GNU Affero General Public License v3.0
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Enable use of use interface shells on intersecting models #11578

Open murk-sy opened 1 year ago

murk-sy commented 1 year ago

Currently, when printing different materials, depending on the combination, having fairly dense interfaces may be required. However, modelling those can be quite difficult and resource consuming in 3D modelling software.

Proposed solution

When having a model with multiple parts loaded, if there are intersecting parts of the models, the intersect of those two models should be considered the "interface volume".

Side view example: yellow is the intersection of the 2 models - an example would be the solid and flexible parts of the tyre. image

With slicing, the material which is used for the intersection alternates: image

I believe this should be relatively simple to implement compared to some sort of interface painting or something like that. If the intersection isn't chamfered and met on point, it could lead to situations where for example a wheel would have a different inside (larger rim) than outside when even number of layers is used. I believe this wouldn't be a major issue - or, in case the adhesion between materials isn't perfect, having multiple solid layers near the outside is likely better, but that's something that can easily be done during modelling.

Stronger interfaces

Currently, the interface consists only of entire layers, which will likely be perfectly functional for most cases.

However, for materials that really don't like each other, some form of hooking may be required.

Top down view example: Odd layer: image Even layer: image

The sketch is a bit terrible, but hopefully it should be a decent enough indication of what I have in my mind. I'll make an actual model or printable example if I'll have time in the coming days.

By using sort of a hook system that is automatically being offset, blue is printed over orange, but the corners of blue (or ornange) are always connecting to themselves.

Therefore, even if 2 materials have terrible adhesion, this sort of interface should be stronger than probably just about anything you could do with injection molding.

freeformz commented 2 months ago

I am running into this issue on my XL where 2 materials are printed "against" one another, but not really locked together.