Scenario:

In order to get more accurate FEA for 3D printed parts I want to get the model as it is printed by the printer, so the sliced part with the printed layers and the infill etc.

I have written a macro that allows me to import a .txt with the points of the extruder head and draw lines in between them.

However, when wanting to sweep along this line it cannot be performed due to self intersecting geometry. However, this self intersection is wanted as during the printing the layers merge together to form the part.

There is a similar question on this forum but I found it not entirely fitting my problem (https://forum.solidworks.com/message/657184?q=Intentionally%20self%20intersecting ). The weldment method works fairly okay, however it creates very sharp geometry. I could go about and fillet those but as there will be hundreds and hundreds of these corners I am looking for a better solution and am currently lost for options.

Note that the extruded profile is roughly a circle with a diameter of +/- 45-50mm. I have added the part file as an attachment.

Thank you for taking a look at this!

Added the .txt files for the tool paths. One is comma separated and the other is tab separated.