From CAD to G-code: Strategies to minimizing errors in 3D printing process

In this study, an analysis was conducted to quantify errors in the additive manufacturing process, with a focus on comparing data files. The primary objective was to minimise the reliance on physical testing of produced components by favouring verification within a virtual environment. The initial focus was on the conversion from the CAD (Computer-Aided Design) model to the STL (Standard Tessellation Language) file, where discrepancies between the two formats were identified. To achieve optimal meshing, it is crucial to configure conversion parameters effectively, avoiding both detail loss and the handling of excessively large files. Following this, a comparison between STL files and reconstructed G-code files was conducted, uncovering further approximations introduced by the most commonly used slicers. In conclusion, the analysis highlights that both the quality of the mesh and the slicing phase significantly impact the final component. Understanding these factors is essential for achieving an optimal print outcome. • Disparities between STEP and STL formats were quantified. • Model discretization into lines and layers contributes to errors in the G-code file. • Examination reveals approximations introduced by the slicers in the G-code generation.