The research on a large-size DLP 3D printing model adaptive slicing algorithm incorporating contour curvature and divide-and-conquer strategy

Purpose This paper aims to address the issue of long slicing times due to the large number of triangular mesh elements in large-size Digital Light Processing 3D (DLP 3D) printing models.It proposes an adaptive slicing optimization method based on curvature. Design/methodology/approach The method introduces model view contours and multiple curvature thresholds, combined with a divide-and-conquer approach to optimize the contour drawing and recognition process, significantly improving slicing efficiency. Findings Experimental results demonstrate that the proposed method reduced slicing time substantially compared to traditional methods. Additionally, the tensile strength, dimensional accuracy and surface roughness of the printed parts were significantly enhanced. The efficiency of the ray-casting method for hole recognition was improved, with the new method processing 0–1000 holes in 0–0.045 s, compared to the traditional method, which took 0–0.75 s for 0–100 holes. The tensile strength of the printed specimens using the proposed algorithm was between 20 MPa and 25 MPa, comparable to those printed with the traditional uniform slicing method. Originality/value The proposed method not only reduces slicing time but also maintains the mechanical properties (tensile strength) and surface quality of the printed models, demonstrating its potential for large-format DLP 3D printing applications.