Three dimensional (3D) printing with stitching of adjacent sub-walls

A method of fabricating a three-dimensional (3D) object from a stereo lithography (STL) file representation of the 3D object stored in a computer readable medium, the method comprising:

• decomposing the STL file into two dimensional slices;
• based upon decomposing the STL file into two-dimensional (2D) slices, determining that a thickness of one or more walls comprising sub-walls of the 3D object are less than a threshold with respect to a width of material deposition of a nozzle;
• modifying a material deposition path for at least one wall of the 3D object, the at least one wall of the 3D object comprising a first sub-wall and a second sub-wall;
• relatively driving the nozzle with respect to a build platform, wherein the 3D object is being fabricated on the build platform;
• depositing, via the nozzle, printing material to fabricate the first sub-wall in a first layer;
• depositing, via the nozzle, printing material to fabricate the second sub-wall in the first layer and adjacent to the first sub-wall according to the modified material deposition path, wherein the second sub-wall is fabricated such that (i) the second sub-wall periodically contacts the first sub-wall, (ii) a void is periodically present between the second sub-wall and the first sub-wall, and (iii) an outer surface of the first sub-wall and an outer surface of the second sub-wall define the thickness of the at least one wall of the 3D object;
• depositing, via the nozzle, printing material to fabricate a first sub-wall of a second layer being a third sub-wall of the 3D object;
• and
• depositing, via the nozzle, printing material to fabricate a second sub-wall of the second layer being a fourth sub-wall of the 3D object and adjacent to the third sub-wall, wherein:
• the third sub-wall is deposited on the first sub-wall and the fourth sub-wall is deposited on the second sub-wall, and
• one of the third sub-wall or the fourth sub-wall is fabricated such that (i) one of the third sub-wall or the fourth sub-wall periodically contacts the other of the fourth sub-wall or the third sub-wall and (ii) a void is periodically present between the third sub-wall and the fourth sub-wall.

A three-dimensional (3D) printer for fabricating a 3D object, the 3D printer configured to:

• receive a digital representation that describes the 3D object in three-dimensional space;
• decompose the digital representation that describes the 3D object in three-dimensional space into two-dimensional slices;
• determine from the two-dimensional slices that a thickness of at least one wall of the 3D object is less than a threshold with respect to a width of material deposition of a nozzle associated with the 3D printer;
• modify a material deposition path for the at least one wall of the 3D object, the at least one wall of the 3D object comprising a first sub-wall and a second sub-wall;
• drive, to fabricate the at least one wall of the 3D object, the nozzle with respect to a build platform of the 3D printer on which the 3D object is to be fabricated;
• deposit, via the nozzle, printing material to fabricate the first sub-wall of the 3D object in a layer;
• and
• deposit, via the nozzle, printing material to fabricate the second sub-wall of the 3D object in the layer and adjacent to the first sub-wall according to the modified material deposition path, the first sub-wall and the second sub-wall in the layer configured to create the thickness of the at least one wall of the 3D object that is less than the threshold, wherein the second sub-wall is fabricated such that (i) the second sub-wall periodically contacts the first sub-wall, (ii) a void is periodically present between the second sub-wall and the first sub-wall, and (iii) an outer surface of the first sub-wall and an outer surface of the second sub-wall define the thickness of the at least one wall of the 3D object.