When we refer to non-planar slicing as being 'for the birds,' we are specifically talking about Joshua Bird, who is making waves in the 3D printing community. He recently showcased his versatile new tool, the non-planar S4-Slicer, by printing a model of the popular Benchy boat upside down using the 'Core R-Theta' printer, a device we have featured previously due to its innovative capabilities.

This new non-planar slicer is ingeniously integrated into a Jupyter notebook environment. This setup employs a relatively straightforward algorithm that automatically generates non-planar toolpaths suitable for any 3D model. The process begins with the creation of a tetrahedral mesh of the model, after which the slicer calculates the most efficient path from any given tetrahedron to the print bed. Despite the non-planar nature of this printing method, it is essential to remember that all prints must still begin from the print bed and work their way up (or outward).

A significant amount of mathematical computation is performed to utilize these paths in order to establish a deformation mesh. While the intricate details of this mathematical process can be complex, Bird has graciously provided an explanatory video for those interested in the technical nuances. Subsequently, once the deformation is applied, he slices the resulting mesh using Cura, a well-known slicing software. The G-code generated from Cura is then sent back to Jupyter for re-transformation, which helps restore the original shape of the mesh, ensuring precision and fidelity in the final printed product.

Indeed, this method can be described as bending G-code in a way that has been demonstrated by others in the past. However, Birds process stands out due to its reproducibility, streamlined approach, and clarity. He attributes much of the progress of this project to earlier developments in the S^3-Slicer, which laid the groundwork for the logic and naming of his S4 slicer. Its important to note that 'S4' does not imply 'more than S^3,' but rather is a contraction of 'Simplified S^3,' signifying an evolution in the slicing process. This exemplifies how open-source development fosters incremental innovation and growth in technology.

While the process is undeniably computationally intensive, Bird notably used a simplified model of Benchy for his demonstration. This type of project is just the kind of task that many in the tech community would relish dedicating their computational power towards, paving the way for further advancements in 3D printing methodologies.

The realm of non-planar 3D printing represents an exciting frontier that has garnered significant attention. Previous explorations in this area have included techniques for non-planar infill and even the ability to print overhangs on unmodified Cartesian printers. However, Birds recent endeavor marks a notable firstthe application of non-planar slicing techniques to the beloved Benchy model. Those interested in trying the S4 slicer can access it through GitHub, or simply enjoy watching the marvel of non-planar printing unfold in the video linked below.