The best way to tell if a 3D print will fail is to monitor the print closely and look for signs of poor quality, such as warping, shifting, stringing, clogging, or cracking. These are some of the most common 3D printing problems that can ruin a print and waste time and material. By detecting them early, you can pause or stop the print and fix the issue before it gets worse.
In this article, we will explain how to identify and prevent some of the most frequent 3D printing failures, and what to do if they happen. We will also provide some tips and resources to help you improve your 3D printing skills and avoid mistakes in the future. Whether you are a beginner or an expert, this article will help you achieve better results with your 3D printer.
Warping is when the edges or corners of a printed part lift off the build plate and curl upwards. This can cause the part to lose its shape and dimensions, and affect its functionality and appearance. Warping is usually caused by uneven cooling of the printed material, which creates internal stresses and forces the part to deform.
To prevent warping, you need to ensure good bed adhesion and consistent temperature throughout the print. Here are some ways to do that:
Use a heated bed and set the temperature according to the material you are using. For example, PLA usually works well at around 60°C, while ABS requires higher temperatures of 90-110°C.
Apply an adhesive layer on the build plate, such as glue, tape, hairspray, or a specialized coating. This will help the first layer stick better and reduce the chances of warping.
Use a brim or a raft to increase the contact area between the part and the build plate. A brim is a thin layer of material that extends from the edges of the part, while a raft is a thicker layer that covers the entire base of the part. Both can be easily removed after the print is done.
Enclose the printer or cover it with a box or a blanket to keep the ambient temperature stable and prevent drafts or fans from cooling the part too quickly.
Shifting
Shifting is when the layers of a printed part are misaligned or offset from each other. This can result in a distorted or skewed part that does not match the original model. Shifting is usually caused by mechanical issues with the printer, such as loose belts, pulleys, screws, or wires, or by external factors, such as vibrations, collisions, or power outages.
To prevent shifting, you need to ensure that the printer is in good working condition and that nothing interferes with its movement. Here are some ways to do that:
Check and tighten the belts, pulleys, screws, and wires on the printer regularly. Make sure they are not too loose or too tight, and that they are not worn out or damaged.
Lubricate the rods, bearings, and other moving parts of the printer occasionally. Use a suitable lubricant, such as silicone oil, grease, or PTFE spray, and apply it sparingly and evenly.
Place the printer on a stable and level surface, away from sources of vibration, such as speakers, fans, or other machines. Avoid touching or moving the printer while it is printing, and make sure nothing bumps into it or blocks its path.
Use a battery backup or a power surge protector to protect the printer from power fluctuations or outages. This will prevent the printer from losing its position or stopping unexpectedly.
Stringing and Oozing
Stringing and oozing are when thin strands or blobs of material are left behind on the printed part or between different parts. This can affect the surface quality and the accuracy of the part, and create unwanted gaps or connections. Stringing and oozing are usually caused by excess material leaking from the nozzle during travel moves, when the extruder moves from one point to another without printing.
To prevent stringing and oozing, you need to control the amount and the flow of material that comes out of the nozzle. Here are some ways to do that:
Use retraction settings in your slicer software. Retraction is when the extruder pulls back the filament slightly before a travel move, to reduce the pressure and the leakage from the nozzle. You can adjust the retraction distance and speed according to your printer and material.
Reduce the printing temperature and increase the printing speed. This will lower the viscosity and the flow rate of the material, and make it less likely to ooze or string. However, be careful not to go too low or too high, as this can cause other problems, such as under-extrusion or overheating.
Use a coasting or a wiping feature in your slicer software. Coasting is when the extruder stops extruding a little before the end of a printing move, to use up the remaining material in the nozzle. Wiping is when the extruder moves along the edge of the part or the infill, to clean the nozzle and remove any excess material.
Clogging is when the nozzle of the printer gets blocked by a piece of filament or a foreign object, and prevents the material from flowing out. This can result in under-extrusion, gaps, or missing layers in the printed part, or even stop the print altogether. Clogging can be caused by various factors, such as low-quality or incompatible filament, incorrect printing settings, or dust or debris in the nozzle.
To prevent clogging, you need to keep the nozzle and the filament clean and clear. Here are some ways to do that:
Use high-quality and compatible filament for your printer and nozzle. Make sure the filament diameter, material type, and color match the specifications of your printer and nozzle. Avoid using old, brittle, or moist filament, as this can break or jam in the nozzle.
Store the filament properly when not in use. Keep it in a sealed bag or a container with a desiccant, such as silica gel, to prevent moisture and dust from entering. Store it in a cool and dry place, away from sunlight and heat sources.
Clean the nozzle regularly and remove any blockages. You can use a needle, a wire, or a special cleaning filament to poke or push out any clogs in the nozzle. You can also heat up the nozzle and extrude some filament manually to flush out any residue or impurities.
Cracking or Layer Separation
Cracking or layer separation is when the layers of a printed part split or detach from each other. This can compromise the strength and the integrity of the part, and make it prone to breaking or falling apart. Cracking or layer separation is usually caused by poor layer adhesion, which is the bond between the layers of the printed material. Poor layer adhesion can be due to insufficient temperature, speed, or cooling settings, or by incompatible materials or models.
To prevent cracking or layer separation, you need to improve the layer adhesion and the cohesion of the printed material. Here are some ways to do that:
Increase the printing temperature and decrease the printing speed. This will allow the material to melt and fuse better, and create a stronger bond between the layers. However, be careful not to go too high or too low, as this can cause other problems, such as overheating or under-extrusion.
Reduce the cooling fan speed or turn it off completely. This will prevent the material from cooling and shrinking too fast, which can create internal stresses and cracks. However, be careful not to overheat the material or the part, as this can cause other problems, such as warping or sagging.
Use the same or compatible materials for the part and the supports. This will ensure that the materials have similar properties and behavior, and that they adhere well to each other. Avoid using materials that have different melting points, shrinkage rates, or chemical reactions, as this can cause the layers to separate or peel off.
Use models that have uniform wall thickness and minimal overhangs or bridges. This will reduce the risk of gaps, holes, or weak spots in the part, and make it more stable and durable. Avoid models that have thin walls, sharp corners, or large spans, as this can cause the layers to crack or break.
3D printing is a fun and rewarding hobby, but it can also be frustrating and challenging at times. There are many factors that can affect the quality and the success of a 3D print, and sometimes things can go wrong without warning. However, by following some simple tips and tricks, you can prevent or fix most of the common 3D printing failures, and improve your 3D printing skills and experience.
We hope this article has helped you learn how to tell if a 3D print will fail, and what to do if it does. If you have any questions or comments, feel free to leave them below. Happy 3D printing!
