Feature Request: Add "Chamfer Along Cut" option to the "Cut" model feature for better post-processing of cut models #610

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MrUnknownDE · 2026-04-05T16:23:57+02:00

MrUnknownDE commented

2026-04-05 16:23:57 +02:00

Originally created by @trebory6 on 2/24/2026

Is there an existing issue for this feature request?

I have searched the existing issues

When post-processing multi-part 3D prints for cosplay, props, or artwork, users often face the challenge of filling seams and gaps.

Without a chamfer along these part seams, the filler material, such as Bondo, tends to sit on top of the model's surface rather than properly within the small gap.

This leads to the filler piling up and creating a subtle bump, which requires multiple passes of filling and sanding to smooth.

Even with repeated sanding and priming, it's difficult to fully feather out this bump, causing the seam to remain visible, especially under reflected light.

This issue is akin to butt-joining flat drywall panels, which also results in a raised area. This is why many dry-wall panels tend to chamfer towards the sides.

Which printers will be beneficial to this feature?

All

Describe the solution you'd like

First of all, I would like to link to this YouTube video which inspired this feature request and goes over the logistics and physics of this solution better than I probably can.

The feature I'd like to add to Orcaslicer adds a "Chamfer along cut" option to the "Cut" Dialogue when cutting a model in Orcaslicer. This OrcaSlicer feature would also give the the user the ability to adjust the size of the chamfer along the cut line, as well as the angle of the chamfer. Possibly also consider a bevel/fillet shape in addition to the chamfer as well.

Other more advanced options might include the ability to only chamfer along one axis(X/Y/Z), or the ability to draw along the cut line on only the parts you want to chamfer, or only chamfer on the outside of the model and not affect internal geometry. Also the option to either extend the chamfer around corners or terminate them at the edge of the corner so corners remain squared.

Inspired by construction techniques like those used in drywall where panels have a slight bevel for mud and tape to sit, the solution is to change the cut seam's geometry before filling.

By adding a small bevel to the edges of the 3D print parts, you create a space for the filler to sit inside the seam between pieces.

This allows the surface to be sanded completely flat, with the filler still occupying the groove, resulting in a seamless finish.

This method also gives the filler more surface area to bond to.

Describe alternatives you've considered

Using a deburring tool manually. Pro: Can be done to any part. Con: Has to be done manually which can result in unevenness.
Cutting in other program: Pro: More control over the model. Con: It requires a separate software.

Additional context

*Originally created by @trebory6 on 2/24/2026* ### Is there an existing issue for this feature request? - [x] I have searched the existing issues ### Is your feature request related to a problem? When post-processing multi-part 3D prints for cosplay, props, or artwork, users often face the challenge of filling seams and gaps. Without a chamfer along these part seams, the filler material, such as Bondo, tends to sit on top of the model's surface rather than properly within the small gap. This leads to the filler piling up and creating a subtle bump, which requires multiple passes of filling and sanding to smooth. Even with repeated sanding and priming, it's difficult to fully feather out this bump, causing the seam to remain visible, especially under reflected light. This issue is akin to butt-joining flat drywall panels, which also results in a raised area. This is why many dry-wall panels tend to chamfer towards the sides. ### Which printers will be beneficial to this feature? All ### Describe the solution you'd like First of all, I would like to link to [this YouTube video](https://www.youtube.com/watch?v=eizuWcrJtYk) which inspired this feature request and goes over the logistics and physics of this solution better than I probably can. The feature I'd like to add to Orcaslicer adds a "Chamfer along cut" option to the "Cut" Dialogue when cutting a model in Orcaslicer. This OrcaSlicer feature would also give the the user the ability to adjust the size of the chamfer along the cut line, as well as the angle of the chamfer. Possibly also consider a bevel/fillet shape in addition to the chamfer as well. Other more advanced options might include the ability to only chamfer along one axis(X/Y/Z), or the ability to draw along the cut line on only the parts you want to chamfer, or only chamfer on the outside of the model and not affect internal geometry. Also the option to either extend the chamfer around corners or terminate them at the edge of the corner so corners remain squared. Inspired by construction techniques like those used in drywall where panels have a slight bevel for mud and tape to sit, the solution is to change the cut seam's geometry before filling. By adding a small bevel to the edges of the 3D print parts, you create a space for the filler to sit inside the seam between pieces. This allows the surface to be sanded completely flat, with the filler still occupying the groove, resulting in a seamless finish. This method also gives the filler more surface area to bond to. ### Describe alternatives you've considered 1. Using a deburring tool manually. Pro: Can be done to any part. Con: Has to be done manually which can result in unevenness. 2. Cutting in other program: Pro: More control over the model. Con: It requires a separate software. ### Additional context 1. [Whiteboard diagrams illustrating the issue with flat seams and how chamfering solves it](https://youtu.be/eizuWcrJtYk?t=37) 2. [Comparison of flat vs. beveled test blocks after filling and sanding](https://youtu.be/eizuWcrJtYk?t=141) 3. [Application of the chamfering technique on real 3D printed armor pieces](https://youtu.be/eizuWcrJtYk?t=247) 4. [Final painted results showing the superior flatness of chamfered seams under reflected light](https://youtu.be/eizuWcrJtYk?t=526)

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Reference: github/OrcaSlicer#610