Question: Circular cylindrical tracks do not fill space. To solve this problem, they can be printed with some overlap (smaller spacing than their diameter) or with
Circular cylindrical tracks do not fill space. To solve this problem, they can be printed with some overlap (smaller spacing than their diameter) or with a flat-tipped nozzle at a layer height smaller than the extrudate (nozzle) diameter, both of which cause lateral spreading of the resin into the void space between tracks before solidification. Consider tracks of diameter D printed at a spacing (center-to-center) of D, but with a flat-tipped nozzle. If the neighboring track is solid and all the spreading of the resin is lateral (i.e., sideways in the cross-section view), show that a flat track (layer) height reduced to about 0.78D would just completely fill space. The drawing shows the shape of the track cross-sections (black) just filling the void space between tracks. This assumes the curvature of the liquid surface of the track being printed (right) stays constant at D and all the lateral spreading is into porosity between the neighboring track (left). Note that the equivalent rectangular track cross- section (red) has width D and the same area as the undeformed circular tracks (blue).
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