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A PrusaSlicer alpha was published on Prusa Research’s GitHub earlier this week, introducing multi-material interlocking and automated arrangement for sequential 3D printing.

Multi-material interlocking should be welcome for Original Prusa XL users, given the system’s particular strength in working with a variety of materials. Prusa cites problems with different materials binding without assistance from interlocking in the alpha’s release notes, but also mentions that binding issues can occur on multi-extruder systems like the XL when using the same material. Interlocking is a new option for adjacent parts that should solve those problems.

The feature originated with UltiMaker’s Cura 5.3 back in 2023, which focused on opportunities to mix soft materials like TPU with more rigid materials for functionalities like a hinge in a clip. At the time, the company said the feature “redefines a multi-material part’s strength as the strength of the weakest of the two materials and not the compatibility of those materials”. Prusa credited both UltiMaker and OrcaSlicer, who previously adapted the feature, in its release notes.

A rendered extruder within PrusaSlicer 2.9.1 during a sequential print preview (Source: Prusa Research)

One change applicable to all users is new features to aid in sequential printing. There’s a new collision detection algorithm, and a new option to arrange parts for sequential printing to avoid collisions; “using sequential printing thus becomes safer and very easy to setup”, Prusa says. The update includes a rendered model of the 3D printer’s extruder during print previews that helps users double-check for potential collisions themselves.

For now, the feature is only available for Prusa 3D printers, with the exception of the MK2 and HT90 – but Prusa says the latter will be supported by release. You can still use sequential arrangement on all printers but, without extruder geometry data, the algorithm uses a simple part clearance radius.

There are a few more improvements and bug fixes in 2.9.1 that you can check out in the PrusaSlicer release notes if you’re keen to give the alpha a whirl.

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