The most common 3D print failure is warping, which occurs when the printed object curls up or deforms from its intended shape due to uneven cooling or poor adhesion to the build plate.
Warping can ruin the appearance and functionality of your 3D prints, and it can be frustrating to deal with. In this article, we will explain what causes warping, how to prevent it, and how to fix it if it happens.
Warping is caused by the difference in thermal expansion and contraction between the layers of your 3D print. When you print an object, the hot filament is extruded onto the build plate and cools down rapidly. As it cools, it shrinks slightly, creating tension between the layers. If the tension is too high, the layers can pull away from each other or from the build plate, causing the object to warp.
Some factors that can increase the risk of warping are:
Material type: Some materials are more prone to warping than others, especially those with high shrinkage rates, such as ABS, nylon, and polycarbonate. PLA and PETG are less likely to warp, but they are not immune to it.
Print temperature: Printing at a higher temperature can increase the thermal stress between the layers, as well as the amount of shrinkage. Printing at a lower temperature can reduce the adhesion between the layers and the build plate, making them easier to peel off.
Bed temperature: The bed temperature affects the adhesion of the first layer to the build plate, as well as the cooling rate of the subsequent layers. A higher bed temperature can improve the adhesion, but it can also slow down the cooling and increase the shrinkage. A lower bed temperature can speed up the cooling and reduce the shrinkage, but it can also weaken the adhesion.
Ambient temperature: The ambient temperature is the temperature of the air around your printer. A colder ambient temperature can cause the layers to cool down faster and unevenly, leading to warping. A warmer ambient temperature can help the layers cool down more uniformly, but it can also increase the overall shrinkage.
Print speed: Printing at a faster speed can increase the thermal stress between the layers, as well as the amount of shrinkage. Printing at a slower speed can reduce the stress and the shrinkage, but it can also affect the quality and the accuracy of the print.
Print geometry: The shape and size of your print can also influence the warping tendency. Objects with large, flat surfaces, thin walls, or sharp corners are more likely to warp than objects with curved, thick, or rounded features. This is because flat surfaces have more contact area with the build plate, thin walls have less structural strength, and sharp corners have higher stress concentrations.
The best way to prevent warping is to optimize your print settings and environment to minimize the thermal stress and the shrinkage of your print. Here are some tips to avoid warping:
Choose the right material: Depending on your application and budget, you may want to choose a material that has a low shrinkage rate and a high resistance to warping, such as PLA or PETG. If you need to use a material that is more prone to warping, such as ABS or nylon, you may need to adjust your print settings and environment accordingly.
Calibrate your printer: Before you start printing, make sure your printer is properly calibrated and leveled. This will ensure that your nozzle height, extrusion rate, and bed alignment are correct, and that your first layer is consistent and well-adhered to the build plate.
Use a heated bed: A heated bed can help you maintain a stable temperature on the build plate, which can improve the adhesion of the first layer and the cooling rate of the subsequent layers. The optimal bed temperature depends on the material you are using, but it is usually around 50-70°C for PLA, 80-100°C for ABS, and 70-90°C for PETG.
Use a bed surface: A bed surface is a material that covers the build plate and provides a better grip for the first layer. There are different types of bed surfaces available, such as glass, PEI, BuildTak, or painter’s tape. The choice of bed surface depends on the material you are using, but it is generally recommended to use a smooth and flat surface for PLA and PETG, and a rough and textured surface for ABS and nylon.
Use a brim or a raft: A brim or a raft is an extra layer of material that is printed around the base of your object, which can increase the contact area and the adhesion to the build plate. A brim is a thin layer that is attached to the object, while a raft is a thicker layer that is separated from the object. A brim or a raft can help prevent warping, especially for objects with small footprints or sharp corners.
Use an enclosure: An enclosure is a structure that surrounds your printer and isolates it from the external environment. An enclosure can help you control the ambient temperature and prevent drafts or temperature fluctuations that can cause warping. An enclosure is especially useful for printing with materials that require a high and consistent temperature, such as ABS or nylon.
Use a cooling fan: A cooling fan is a device that blows air onto your print to speed up the cooling and solidification of the layers. A cooling fan can help improve the quality and the accuracy of your print, as well as reduce the warping tendency. However, a cooling fan can also cause thermal shock and cracking if used too aggressively, especially for materials that are sensitive to temperature changes, such as ABS or nylon. Therefore, you may need to adjust the fan speed and the direction depending on the material and the geometry of your print.
If you encounter warping during or after your print, there are some ways to fix it or reduce its impact. Here are some solutions to deal with warping:
Pause or abort the print: If you notice warping early in your print, you may want to pause or abort the print and adjust your settings or environment before resuming or restarting the print. This can save you time and material, and prevent further damage to your print or your printer.
Use a heat gun or a hair dryer: If you have a minor warping issue, you may be able to fix it by applying some heat to the warped area using a heat gun or a hair dryer. This can soften the material and allow you to bend it back to its original shape. However, be careful not to overheat or burn the material, and wear gloves to protect your hands from the heat.
Use a clamp or a vice: If you have a moderate warping issue, you may be able to fix it by clamping or vicing the warped area to a flat surface, such as a metal plate or a wooden board. This can apply some pressure and force the material to conform to the shape of the surface. You may need to heat the material first to make it more pliable, and leave it clamped or viced for some time to let it cool down and set.
Use a filler or a glue: If you have a severe warping issue, you may not be able to fix it by bending or clamping the material. In that case, you may need to use a filler or a glue to fill in the gaps or cracks caused by the warping. You can use a material that matches the color and the properties of your print, such as epoxy resin, super glue, or 3D pen filament. You may need to sand or polish the surface after applying the filler or the glue to smooth out the imperfections.
Warping is the most common 3D print failure, and it can ruin your 3D printing experience and results. However, warping is not inevitable, and it can be prevented or fixed by following some simple tips and tricks. By choosing the right material, calibrating your printer, using a heated bed, a bed surface, a brim or a raft, an enclosure, and a cooling fan, you can minimize the thermal stress and the shrinkage of your print, and avoid warping. If you do encounter warping, you can fix it by using a heat gun, a hair dryer, a clamp, a vice, a filler, or a glue, depending on the severity of the issue. We hope this article has helped you understand what causes warping, how to prevent it, and how to fix it, and that you can enjoy your 3D printing hobby without any hassle.
