Shape deviation is one of the major issues in fabricating a part using Additive Manufacturing (AM) technology. During the prototype fabrication process, slicing induced conditions play a significant role in varying shape deviations. This paper provides a novel technique for the estimation and simulation of shape deviation and provides a foundation to estimate the combined effect of oversize and undersize fabrication conditions on the same layer. The research described is the initial efforts to develop a shape deviation model regarding oversize, undersize, equal size and mixed size situations. To estimate and simulate the shape deviation, an algorithm is developed and examined with seven example tessellated prototypes. The advanced program will help the user to determine the different shape deviation information during slicing stage with different preprocessing parameters. The results show that the developed methodology is robust and work as an efficient alternative to shape deviation studies.

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