3D printing is a rapidly growing technology that allows people to turn digital designs into physical objects. It can allow for the creation of complex & intricate objects with ease. However, as with any technology, it can come with its own set of challenges that arise when 3D printing an object. In this post, we will explore some of the most common issues encountered when 3D printing and provide solutions & suggestions for dealing with each problem.
Problem: Warping
One of the most common problems encountered with 3D printing is warping. Warping occurs when the edges of the printed object lift up and curl away from the build plate. This can be caused by a number of factors including improper bed leveling, insufficient adhesion, or incorrect temperature settings.
Solutions for Warping
To solve this problem, you can try using a heated build plate, increasing the temperature of the build chamber (if your 3D printer has an enclosed chamber), or using a brim or raft to increase adhesion to the build plate.
Other Potential Solutions for Warping:
- Increasing the build plate adhesion by using adhesive sprays or glue stick.
- Using a larger brim or raft to increase the surface area in contact with the build plate.
- Using a cooled build plate to help the plastic cool and solidify more quickly.
- Using an enclosure to maintain a consistent temperature and humidity.
- Using a flexible or flexible-like material for the build plate.
- Decreasing the print speed to allow the printed object to cool down before the next layer is added.
- Using a cooling fan to cool the printed object as it is being printed.
- Lowering the print temperature.
- Using a bed surface specifically designed for the filament you are using.
- Using a build plate with a textured surface to increase adhesion.
- Using a build plate that can be heated and cooled.
Problem: Overhangs & Bridges
Overhangs and bridges can occur when an object has a section that hangs unsupported in the air. This can be caused by poor geometry or orientation of the object.
Solutions for Overhangs & Bridges
To solve this problem, you can try adjusting the orientation of the object by re-slicing it to minimize the amount of overhang, or using a support material that can be easily removed after printing.
Other Potential Solutions to Overhangs & Bridges
- Increasing the infill percentage to add more internal support to the object.
- Modifying the design to reduce overhangs or add support structures.
- Using a flexible filament which can bend slightly instead of breaking.
- Using a higher temperature for the filament to make it more flexible.
Problem: Stringing
Stringing: Stringing (or oozing) occurs when small strings of filament are left between the printed object and the nozzle. This can be caused by improper retraction settings or incorrect nozzle temperature.
Solutions for Stringing
To solve this problem, you can try decreasing the temperature of the nozzle, slowing down the print speed, or adjusting the retraction settings on your printer. You might to tinker with both the retraction distance and/or the retraction speed. I have a entire post on how we dealt with our stringing issue with our Creality Ender 3 HERE (Retraction in Action! Eliminate Stringing & Improve the QUALITY of Your 3D Printed Models)
Other Potential Solutions for Stringing
- Make sure retraction is enabled in your slicing software.
- Increasing the retraction distance
- Increaqsing the retraction speed.
- Limit support retractions.
- Maximize retraction count.
- Enabling coasting in your slicing software.
- Enabling wiping in your slicing software.
- Enabling combing in your slicing software.
- Enabling z-hop in your slicing software.
- Adjusting the minimum extrusion distance window in your slicing software.
- Setting the retraction minimum travel in your slicing software.
- Nozzle Switch Retraction Distance, Nozzle Switch Retraction Speed, Nozzle Switch Retract Speed, Nozzle Switch Prime Speed and Nozzle Switch Extra Prime Amount are all only relevant for 3D Printers with more than one printing nozzle. Since this does not apply to single nozzle printers – just leave it at the default settings. My understanding is that CURA does not like you reducing any of these settings to 0.
Problem: Layer Separation
Layer separation occurs when layers of the printed object separate from one another during printing. This can be caused by improper temperature settings, incorrect flow rate, or poor cooling.
Solutions for Layer Separation
To solve this problem, you can try increasing the temperature of the filament, slowing down the print speed, or adjusting the flow rate of the filament.
In addition, you can try adjusting the bed leveling, which will help to ensure that the object is printed at the correct height and with proper adhesion to the build plate.
Problem: Over-Extrusion or Under-Extrusion
Over-extrusion or under-extrusion occurs when too much or too little filament is extruded during printing. This can be caused by improper flow rate settings or incorrect nozzle temperature.
Solutions to Over-Extrusion or Under-Extrusion
To solve this problem, you can try adjusting the flow rate of the filament, or adjusting the temperature of the nozzle. If you are experiencing over -extrusion – try lowering the temperature of the print nozzle. If you are experiencing under-extrusion – try increasing the temperature nozzle so the melted filament flows more easily.
Problem: Clogging
Clogging occurs when the filament gets clogged inside the nozzle. This can be caused by a build-up of debris or a change in filament. Cold pulling your filament when changing spools can also cause clogging.
Solutions to Clogging
To solve this problem, you can try heating the nozzle to a high temperature, using a needle to clear out the clog, or replacing the nozzle.
Other Potential Solutions for Clogging
- Keeping the filament dry and well-stored.
- Cleaning the filament before using it.
- Reducing the layer height to reduce the amount of filament used.
- Using a filament with a smaller diameter.
- Using a cleaning filament or wire to clear the clog.
- Heating the nozzle to a high temperature to melt the clog.
- Keeping the filament path clean.
- Using a more durable nozzle that can better withstand the heat and pressure of 3D printing.
- Changing the print speed if it’s too fast.
- Using a different type of filament that is less prone to clogging.
- Remove the nozzle and soak in acetone to remove the clog, then re-install the nozzle.
- Replacing the nozzle if the problem persists.
Problem: Poor Bed Adhesion
Poor bed adhesion is when your 3D print does not stick (or adhere) to the build plate. If the very first layers of the filament being extruded do not properly stick to the build plate the entire print my fail. This can be caused by a dirty build plate or incorrect temperature settings.
We have even experienced this well after the print has begun. In our situation the 3D printer is in the back room of the basement – which is not a heated room. We usually close the door to this room to minimize any fumes escaping the printing room. As a result, during the colder months, the room can drop pretty significantly during a multi-hour print. This, in turn, has caused the model to contract and pull away for the build plate entirely. I once went down there and could see the printer still trying to print the model – which was just literally sliding on the build plate while the extruder continued to create a spaghetti mess in the build chamber.
Solutions to Poor Bed Adhesion
To solve this problem, you can try cleaning the build plate, applying an adhesive spray or glue stick, or using a tape on the build plate.
Other Potential Solutions for Poor Bed Adhesion
- Using a specialized bed surface or tape to increase adhesion.
- Ensuring that the bed is level and clean.
- Using a heated bed to increase adhesion.
- Using a build plate with a textured surface to increase adhesion.
- Using a build plate that can be heated and cooled.
- Using a build plate with a high coefficient of thermal expansion.
- Using a build plate that can be cooled quickly.
- Cleaning the bed with isopropyl alcohol or acetone.
- Using a flexible or flexible-like material for the build plate.
- Using a bed adhesive like hairspray, glue stick or blue tape.
- Using a build plate with a roughened surface.
- Ensuring that the room temperature doesn’t vary significantly over the entire course of the printing time.
- Offsetting the potential change in the room temperature with an increase in the building chamber temperature – if your printer has a heated build chamber like the Qidi Technology iFast 3D Printer.
Problem: Incorrect Model Orientation
Incorrect model orientation occurs when the model is oriented in a way that leads to poor quality or failed print. This can be caused by poor model design or incorrect support structure settings. We recently experienced this with a model Dominick was making of an atom of magnesium. We are embarrassed to admit that it took us SEVERAL tries at printing the model before we identified the problem as being the model orientation!
Solutions to Incorrect Model Orientation
To solve this problem, you can try rotating the model to a better orientation or adjust the support structure for the model. In our case – we had to re-position the model in TinkerCAD and then re-slice the model. We were relieved that there wass a problem with our brand-new printer, but rather just a silly oversight in the model’s orientation.
Other Potential Solutions for Incorrect Model Orientation
- Experimenting with different orientations and support structures to find the best solution.
- Using software to analyze the model and identify potential issues.
- Consult the manual or the manufacturer’s website for specific instructions or troubleshoot guides.
- Using a slicing software that has the option to automatically orientate the model.
- Using a support structure that can be easily removed.
- Using a support structure that is similar in material to the model.
- Using a support structure that is similar in color to the model.
- Using a support structure that can be sanded or filed.
- Using a support structure that can be dissolved with a solvent.
- Using a support structure that can be broken or cut away.
Problem: Blurred or Low-Quality Details
Blurred or low-quality details: This can occur when the layer height is set too high, or when the print speed is too fast.
Solutions to Blurred or Low-Quality Details
To solve this problem, you can try decreasing the layer height and/or slowing down the print speed.
Other Potential Solutions to Blurred or Low-Quality Details
- Decreasing the layer height to make the layers more robust
- Decreasing the print speed to reduce the amount of time the filament is molten
- Increasing the infill percentage to add more internal support to the object
- Using a higher quality filament that can produce finer details
- Using a higher resolution for the 3D model
- Using a smaller nozzle size for more precise details
- Checking and adjusting the temperature of the filament to ensure that it is the correct temperature for the filament being used
- Checking and adjusting the flow rate settings to ensure that the correct amount of filament is being extruded
- Checking and adjusting the printer settings like the bed leveling, bed temperature, and the cooling system to ensure that the object is printed in the best conditions.
- It’s important to note that some models might need to be redesigned or print at a different scale if the details are too small or complex to be printed, also, the specific solution will depend on the printer and the specific circumstances of the print.
Problem: Curling or Delamination of the First Layer
Curling or delamination of the first layer: This can occur when the bed leveling is not correct or the bed temperature is too low.
Solutions to Curling or Delamination of the First Layer
To solve this problem, you can try re-leveling the bed and/or increasing the bed temperature.
Other Potential Solutions to Curling or Delamination of the First Layer
- Re-leveling the bed to ensure that the first layer is applied evenly.
- Checking and adjusting the bed temperature to ensure that it is at the correct temperature for the filament being used.
- Applying an adhesive solution or using an adhesive bed surface to increase adhesion.
- Increasing the nozzle temperature to make the filament more fluid.
- Decreasing the print speed to reduce the amount of time the filament is molten.
- Checking and adjusting the flow rate settings to ensure that the correct amount of filament is being extruded.
- Using a thicker first layer or applying a brim or raft to increase adhesion to the build plate.
- Using a flexible filament which can bend slightly instead of breaking.
- Checking and adjusting the fan speed to ensure that the cooling is adequate to solidify the filament before the next layer is applied.
Problem: Nozzle Jamming
This can occur when the filament is not fed through the extruder properly.
Solutions to Nozzle Jamming
To solve this problem, you can try cleaning the extruder, adjusting the filament tension, or replacing the extruder.
Other Potential Solutions to Nozzle Jamming
- Checking and adjusting the filament tension to ensure that the filament is fed through the extruder properly.
- Cleaning the extruder and the feeder gear to remove any debris or build-up.
- Checking and adjusting the temperature of the extruder to ensure that it is at the correct temperature for the filament being used.
- Checking and adjusting the flow rate settings to ensure that the correct amount of filament is being extruded.
- Using a cleaning filament or wire to clear the jam.
- Reducing the print speed if it’s too fast.
- Checking and adjusting the retraction settings to ensure that the filament is being pulled back correctly.
- Using a different type of filament that is less prone to jamming.
- Replacing the extruder if the problem persists.
Problem: Temperature Issues
Temperature issues can occur when the temperature of the extruder or bed is not set correctly.
Solutions to Temperature Issues
To solve this problem, you can try adjusting the temperature settings and/or cleaning the thermal sensor.
Other Potential Solutions to Temperature Issues
- Checking and adjusting the temperature of the extruder and the bed to ensure that they are at the correct temperature for the filament being used.
- Cleaning the thermal sensor to ensure that it is working correctly.
- Checking and adjusting the fan speed to ensure that the printer is being cooled properly.
- Checking and adjusting the flow rate settings to ensure that the correct amount of filament is being extruded.
- Insulating the printer to maintain the temperature.
- Checking and adjusting the power supply to ensure that the printer is receiving enough power.
- Increasing the print speed if the object is not heating up enough.
- Lowering the print speed if the object is overheating.
- Checking and adjusting the voltage and amperage of the power supply.
- Checking and adjusting the thermistor settings.
- Using a different type of filament that is less prone to temperature issues.
Problem: Incorrect / Inconsistent Filament Diameter
This can occur when the filament diameter is not consistent, which can cause issues with extrusion.
Solutions for Incorrect / Inconsistent Filament Diameter
To solve this problem, you can try using a filament with a consistent diameter or adjusting the flow rate.
Other Potential Solutions for Incorrect / Inconsistent Filament Diameter
- Measuring the filament diameter to ensure that it is consistent.
- Using a better filament with a more consistent diameter.
- Adjusting the flow rate of the filament to ensure that the correct amount of filament is being extruded.
- Checking and adjusting the temperature of the filament to ensure that it is at the correct temperature for the filament being used.
- Cleaning the extruder and the feeder gear to remove any debris or build-up.
- Checking and adjusting the filament tension to ensure that the filament is fed through the extruder properly.
- Checking and adjusting the retraction settings to ensure that the filament is being pulled back correctly.
- Using a different type of filament that is less prone to diameter inconsistencies.
- Using a filament with a smaller diameter if the extruder can handle it.
- Using a filament with a larger diameter if the extruder can handle it.
Problem: Large Holes or Gaps in the 3D Printed Object
Large holes or gaps in the print can occur when the print speed is too fast or the layer height is too low.
Solutions to Large Holes or Gaps in the 3D Printed Object
To solve this problem, you can try slowing down the print speed and/or increasing the layer height.
Other Potential Solutions to Large Holes or Gaps in the 3D Printed Object
- Decreasing the print speed to reduce the amount of time the filament is molten.
- Increasing the infill percentage to add more internal support to the object.
- Modifying the design to reduce overhangs or add support structures.
- Checking and adjusting the flow rate settings to ensure that the correct amount of filament is being extruded.
- Checking and adjusting the nozzle size to ensure that it is the correct size for the filament being used.
- Checking and adjusting the temperature of the filament to ensure that it is at the correct temperature for the filament being used.
- Decreasing the layer height to make the layers more robust.
- Using a different type of filament that is more rigid.
- Using a higher quality filament that can produce finer details.
- Using a higher resolution for the 3D model.
- Using support structures to hold the model in place while printing.
Problem: Difficulty Removing Support Material
Supports are both blessing and a curse! They allow you to print structures and objects that you would not otherwise print – but they can be extremely cumbersome to deal with! Far too often we have damaged or destroyed a print while trying to remove the supporting structures.
Solutions for Difficulty Removing Support Material
To solve this problem, you can try using a support material that is easier to remove (water soluble – if you have a dual extruder 3D printer), adjusting the support structure settings, or trying to re-orient the object so you don’t need to use supporting structures.
Other Potential Solutions for Difficulty Removing Support Material
- Using a water-soluble support material that can be easily dissolved away (if you have a dual extruder 3D printer).
- Using a support material that can be easily broken or cut away.
- Using a support material that can be easily sanded or filed away.
- Increasing the temperature of the support material to make it more pliable.
- Decreasing the temperature of the support material to make it more brittle.
- Using a tool specifically designed for removing support material, such as a specialized scraper or needle tool.
- Using a solvent to dissolve the support material.
- Using a combination of mechanical and chemical methods to remove the support material.
- Using a support material that is easier to remove, such as HIPS (High Impact Polystyrene).
- Using a support material that is similar to the material that the model is made from so that it’s easier to remove.
In conclusion, while 3D printing can be a very rewarding and satisfying experience, it’s important to be prepared for the challenges that may arise.
It’s important to remember that each 3D printer can have different specific issues and solutions, and the best way to troubleshoot is often a combination of consulting the manual or the manufacturer’s website for specific instructions or troubleshoot guides and finding forums and blogs like ours to help you trouble shoot your problems.
By understanding some of the most common problems and how to solve them, you can increase the chances of successful 3D printing your models & objects and ensure that your 3D printing journey is as smooth as possible.
Sincerely,
