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A Slicer-Independent Framework for Measuring G-Code Accuracy in Medical 3D Printing
Michel Beyer1,2, Alexandru Burde3, Andreas E Roser1,2
1Department of Oral and Cranio-Maxillofacial Surgery, University Hospital Basel, 4031 Basel, Switzerland.
Journal of Imaging
|January 27, 2026
Summary
Slicing software significantly impacts 3D printing accuracy. This study quantified deviations introduced by five slicers, finding errors below 0.1 mm, crucial for medical applications.
Area of Science:
- Biomedical Engineering
- Additive Manufacturing
- Computational Geometry
Background:
- Accuracy in medical 3D printing is vital for patient-specific implants and anatomical models.
- While printer performance is studied, the impact of slicing software on geometric fidelity remains less quantified.
- The conversion of STL files to G-code by slicers can introduce deviations affecting final print accuracy.
Purpose of the Study:
- To quantify slicer-induced G-code deviations by comparing G-code-derived geometries with their reference STL models.
- To assess the influence of different slicing software on the geometric fidelity of 3D printed medical models.
- To determine which slicing software introduces the least geometric error in the FDM workflow.
Main Methods:
- Twenty mandibular models were processed using five slicers: PrusaSlicer, Cura, Simplify3D, Slic3r, and Fusion 360.
- A custom Python workflow converted G-code to point clouds and reconstructed STL meshes with XY/Z corrections and surface extraction.
- Accuracy was evaluated using Mean Surface Distance (MSD), Root Mean Square (RMS) deviation, and Volume Difference, with a calibration object for normalization.
Main Results:
- Slicer-induced Mean Surface Distance (MSD) ranged from 0.071 to 0.095 mm, and Root Mean Square (RMS) deviation from 0.084 to 0.113 mm.
- Volumetric differences were dependent on the slicing software used.
- PrusaSlicer demonstrated the highest surface accuracy, while Simplify3D and Slic3r exhibited the best repeatability. Fusion 360 yielded the largest deviations.
Conclusions:
- Slicing software introduces geometric deviations below 0.1 mm, representing a significant portion of the overall error in Fused Deposition Modeling (FDM) workflows.
- The choice of slicing software critically influences the geometric accuracy of 3D printed medical models.
- Understanding and mitigating slicer-induced errors are essential for advancing the reliability of medical 3D printing.
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