An algorithm has been developed to estimate the “horizontal” staircase effect and a technique is proposed to reduce this type of geometrical error for freeform extrusion fabrication processes of 3D “solid” parts. The adaptive rastering technique, proposed in this paper, analyzes the geometry of each layer and changes the width of each line of the raster adaptively in order to reduce the staircase error and increase the productivity simultaneously. For each line, the maximum width that results in a staircase error smaller than a predefined threshold is determined for decreasing the fabrication time or increasing the dimensional accuracy, or both. To examine the efficacy of the proposed technique, examples are provided in which staircase errors and fabrication times are compared between uniform and adaptive rastering methods for each part. The results show a considerable improvement in accuracy and/or fabrication time for all parts studied when using the adaptive rastering technique.

Meeting Name

26th Annual International Solid Freeform Fabrication Symposium -- An Additive Manufacturing Conference, SFF 2015 (2015: Aug. 10-12, Austin, TX)


Mechanical and Aerospace Engineering

Research Center/Lab(s)

Intelligent Systems Center


The authors gratefully acknowledge the financial supports by the National Energy Technology Laboratory of the U.S. Department of Energy’s Office of Fossil Energy under the contract DE-FE0012272, and the Intelligent Systems Center at the Missouri University of Science and Technology.

Document Type

Article - Conference proceedings

Document Version

Final Version

File Type




Publication Date

12 Aug 2015

Included in

Manufacturing Commons