Failures in 3D printing are common, particularly for beginners.
Here are typical 3D printing problems and their causes. Also, solutions and general prevention tips.
Shrinkage
Cause:
- Quick layer cooling
- Wet plastic
- Low-quality plastic
Solution:
- Boost the speed of printing
- Raise the height of the layer
- Dry the plastic
Shrinkage in plastics occurs when they lose volume upon solidification, influenced by factors like printing region temperature, melting point, and material quality.
High moisture content in raw materials increases shrinkage and cavity formation. Utilizing specific filaments can minimize shrinkage without additives, while adjustments in layer height and printing speed can address defects.
To maintain consistent plastic volume during printing, selecting appropriate conditions is crucial, particularly for fusible plastics melting above 300°C, as higher temperatures may cause overheating, curling, stringing, and over-extrusion.
Warping
Cause:
- Thermo-mechanical stresses in the component while it cools
- Excessive length-to-width ratio
- Wall density
- Elevated infill proportion
Solution:
- Preserve a steady temperature
- Clean the surface of the table
- Apply adhesives
- Lower the infill percentage to under 20 percent
- Steer clear of employing more than two or three perimeter shells
- Increase the brim
Warping is a defect in printed parts that results in loss of flatness, observable by sight or measurement.
It arises from thermomechanical tensions during cooling and changes in the polymer’s volume during crystallization.
Factors such as the part’s height, length-to-breadth ratio, wall thickness, and infill percentage are significant in defect formation.
Conditions like excessive cooling, inappropriate adhesives, and unclean heating beds can exacerbate these issues, potentially altering the part’s shape and rendering it unusable.
Additionally, raised sections may obstruct the nozzle, causing print interruptions.
Layer Shifting
Cause:
- Erroneous extruder motion
Solution:
- Examine the positioning system axis’s moving components for backlash and mechanical damage.
- Change the 3D model to avoid tricky geometry.
- Concentrate on areas with large overhangs because they may deform during printing.
The layer shifting problem is visually represented by the inaccurate placement of a layer in relation to the preceding layer.
This mistake shows up as shifts along the X or Y axes. Such faults may be small, staying within the extrusion width.
They don’t cause major geometric issues or weaken the part’s physical-mechanical properties.
Excessive shifts can cause poor printing results. This happens when layers fail to connect with the parts printed before.
The flaw in the printed part is caused by incorrect movement of the extruder.
Blocked axis movement, loose pulleys, and tough part shapes can cause layer shifting.
This leads to weaker strength, a compromised structure. Moreover, changes to the original 3D model.
Inspect the positioning system axes for mechanical damage and backlash.
This helps prevent defects. The 3D model must avoid tricky printing shapes. This is important for big overhangs that might bend while printing.
Delamination
Cause:
- High material shrinkage
- Low heating bed or extruder temperature
- Too much cooling or fanning
Solution:
- Keep the air temperature stable
- Cover the printing area to block air currents
- Raise the extruder’s temperature by five to ten degrees Celsius
The layered nature of FFF printing results in anisotropic mechanical properties. Products have more tensile strength when stress is applied. Along the layers instead of across them.
Utilizing ultra-high extrusion widths can mitigate this anisotropy.
Weak layer bonding can cause delamination. Cracks form between layers and follow their direction, marking this.
This usually initiates at the edges and corners of parts before propagating. Additionally, minor flaws can act as stress concentrators, triggering delamination.
Delamination happens when two layers split apart. This occurs when the bond between them weakens due to internal tensions.
Delamination negatively impacts the part’s mechanical and physical properties.
To prevent issues, keep a steady ambient temperature.
Cover the printing area to block air currents. Also, raise the printing temperature by 5 to 10°C. This boosts adhesion and lowers viscosity.
Curling
Cause:
- 1) If the material gets too hot or isn’t cooled enough, it can stick to the nozzle and the material that comes out.
- 2) Plastic spreading shows overheating.
Solution:
- Slow down the printing speed
- Boost the part’s cooling intensity
- Lower the extruder’s temperature by 5 to 10°C
Curling is a flaw that looks like warping.
It happens in the upper corners of a part when it gets too hot and deforms.
Overheating can cause material to stick to the nozzle. This leads to defects as the plastic spreads, affecting the part’s shape.
Lower the extruder temperature by 5 to 10°C to prevent faults.
Also, increase the fan intensity and slow down the printing speed. This gives more time for cooling.
Be careful when changing temperature settings.
Doing so can cause defects due to low material, part, or print area temperatures.
Gaps
Cause:
Poor adherence between strands and layers.
Solution
- Raise the heated bed and extruder temperature.
- Decrease the printing speed.
- Increase extrusion width and decrease layer height
- Raise the part’s infill percentage
Cavities are gaps up to 1 mm in different shapes. They happen due to weak adhesion between strands and layers in 3D printing. This weakness comes from limited melt flow, diffusion, and rapid cooling.
Factors that affect mechanical strength and permeability are:
- Higher extruder and bed temperatures
- Slower speeds
- Lower layer heights
- Wider extrusion
- Increased infill percentage, which cuts down internal porosity.
Additionally, ironing can enhance the surface finish by smoothing the top layer.
Stringing
Cause:
- High extruder temperature
- Incorrect retraction setting
Solution:
- Increase the retraction distance
- Lower the extruder temperature
- Slow down the printing speed
- Calibrate the bed correctly on the Z-axis
Stringing, or oozing, happens when thin threads of material form between parts of a 3D printed object. This happens when material sticks to the nozzle while moving, but without using thermoplastic.
It often results from high extruder temperatures, which cause uncontrolled material flow. Stringing can distort the final product’s shape and size.
Over-extrusion
Cause:
- Elevated temperature of the extruder
- A high multiplier for extrusion
Solution:
- Lower the temperature of the extruder
- Lower the extrusion multiplier
Too much material feeds into the extruder, causing over-extrusion.
This causes the product to differ from the digital model.
High temperatures and feeding rates are the main reasons for this issue.
The flaw can be local or widespread. One possible cause is a drop in extruder speed when printing while turning. Over-extrusion can improve tensile strength, but it can also ruin the shape and size.
To mitigate this issue, it is essential to lower the extruder temperature and feeding rate.
Under-extrusion
Cause:
- Low extruder temperature
- Low multiplier of extrusion
Solution:
- Raise the temperature of the extruder
- Boost the extrusion multiplier
Overfeeding causes over-extrusion. This leads to inconsistencies in the digital model. As a result of high extruder temperatures and feeding rates.
This flaw can be either localized or widespread, and a reduction in extruder speed may play a role in the issue.
Over-extrusion boosts tensile strength, but it also distorts the product’s shape and size.
To avoid this issue, lowering the extruder temperature and feeding rate is necessary.
Banding
Cause:
- Lack of materials
- Unclear Z-axis position of the heated bed
Solution:
- Check the Z-axis
- Remove any blockages in the nozzle.
- Raise the temperature of the extruder or the extrusion multiplier.
The term “banding” describes uneven surfaces on a printed product. It shows up as wavy textures or clear lines.
This defect happens because of wobbling and inadequate of material.
It stems from problems with the Z-axis heating bed placement and not enough material extrusion.
To prevent banding, fix both wobbling and extrusion issues.
Check for nozzle clogs. Adjust the extruder’s temperature and extrusion multiplier if needed.
Cracks
Cause:
- Voids are what cause cracks to form under load
Solution:
- Make the part less porous;
- Use a nozzle with a bigger diameter
- Raise the height of the layer
Cracks may develop in 3D printed objects made from materials like ceramics and metals.
Particularly under operational stress, which affects their fatigue strength.
These cracks typically start at the material’s weakest points.
Often occurring along the printing path and between layers during the printing process.
Cracks form in materials under pressure due to voids acting as stress concentration points.
Reducing porosity can enhance resistance to cracking.
This is achieved by minimizing layer height during printing. Increasing nozzle size and layer height may decrease the rate of fatigue.
Fracture propagation, as suggested by bending experiments.
Blobs
Cause:
- The start and end travel points have incorrect filament retraction settings.
- Variations in filament diameter
Solution:
- Choose the appropriate filament retraction parameters.
- Make use of a stable-diameter, high-quality filament.
Blobs on a printed part’s surface manifest as swells or bubbles.
It is caused by incorrect filament retraction settings and filament diameter stability.
These defects can impact the part’s geometric and aesthetic qualities.
Leading to nozzle catch that disrupts printing.
To resolve this, it’s recommended to use filament with minimal thickness variations.
Adjust retraction settings if filament quality is not the issue.
Voids
Cause:
- The collection of moisture because the material is hygroscopic
- Poor material layer adherence during printing
Solution:
- Let the filament dry
- Raise the temperature of the extruder
- Increase extrusion width and decrease layer height
- Raise the part’s infill percentage
Voids or pores are substance-deficient areas in a product.
Generally smaller than gaps, found in layers, on surfaces, and near-surface layers.
They compromise mechanical properties, lowering maximum load and tensile strength.
This raises vulnerability to environmental factors due to increased contact area.
Increased interlayer holes negatively impact fatigue strength, particularly under perpendicular loads.
Leading to potential delamination. Cracks may arise from vacancies during use and poor interlayer adherence.
During the printing phase it creates pores.
To mitigate these issues, one can increase printing temperature, reduce layer height.
Gradually raise the extrusion rate to minimize pore formation. Utilizing a square-shaped nozzle also helps decrease the number of pores.
Computational fluid dynamics suggests that reduced porosity occurs with thinner layers.
Moisture in the filament can lead to inconsistent flow and the formation of pores. This may be alleviated by pre-drying.
Additionally, environmental humidity impacts porosity and several post-processing techniques.
Solvent immersion or vapor treatment can improve surface smoothness and reduce surface pores.
Annealing improves stress redistribution, crystallinity, and strength in materials, especially semicrystalline ones.
It requires heating between the glass transition and melting temperatures.
In the case of amorphous polymers like ABS, annealing also decreases overall porosity.
Molecular cleavage
Cause:
- Heating the filament when printing
Solution:
- Make use of premium filaments
- Prevent localized material overheating
Overheating of the filament during printing can lead to thermal breakdown of the polymer. By cleaving chemical bonds and breaking the polymer chain.
This process results in the formation of new products with distinct characteristics.
It might cause non-homogeneous material qualities and flaws like porosity. Moreover, the breakdown may release harmful gases.
Overheating polyoxymethylene (POM) during printing can lead to its breakdown.
The release of formaldehyde vapor, starting at 160 °C due to auto-oxidation.
The polymer’s thermal degradation is influenced by its chemical bond structure.
Infrared spectroscopy indicates that polyethylene terephthalate degrades at 450 °C. With vleaving ester bonds and producing carbon monoxide, carbon dioxide, benzoic acid, and its derivatives.
Materials commonly used in FFF printing, such as PLA, ABS, and nylon, are prone to thermal degradation.
Even at temperatures close to printing levels. When heated at 240–250°C for ten minutes, they release a mix of volatile products.
Like ABS emits acetone, butadiene, styrene, isobutanol, ethylbenzene, and cyclohexanone.
PLA releases acetone, methyl methacrylate, isobutanol, and cyclohexanone; while nylon gives off propylene glycol and cyclopentanone.
To prevent defects in 3D printing, it is essential to use high-quality filaments and control printing conditions.
To mitigate localized overheating. Improper storage of thermoplastics can lead to deterioration.
Specifically, polylactide undergoes hydrolytic breakdown at temperatures over 37°C. Diminishing its molecular weight and degrading the mechanical properties of the final printed products.
A major advancement in manufacturing technology is 3D printing, which has seen the development of various techniques for producing goods from multiple materials.
Selecting optimal printing parameters remains essential, as it significantly affects the performance characteristics of the manufactured items.
In order to compose this following piece, I researched 3D Printing Troubleshooting Guide: Top 14 Problems and Solutions
Clogged nozzles or a jammed extruder
Cause:
- Debris from outdated or poor-quality filament can accumulate over time, leading to filament residue.
- Printing at incorrect temperatures can cause filament flow issues or nozzle deterioration.
- Dust or dirt in filament can cause contamination of the nozzle.
- Changing filament types can lead to nozzle clogging due to residues from incompatible materials.
Solution:
- Perform a cold pull by heating the nozzle to the filament’s recommended temperature and extrude until the filament flows freely.
- After slightly cooling the nozzle, remove the filament to clear debris, and repeat if needed.
- To remove obstructions, insert a 4 mm thin cleaning needle into the nozzle carefully, avoiding damage to the interior.
- Disassemble and Clean by Hand: Take the printer’s nozzle out. To clean the nozzle, soak it in acetone to eliminate ABS residue, heat it for other filaments like PETG or PLA, and use a soft wire brush or cleaning filament to remove any remaining residue.
- Make sure the cleaned nozzle is totally dry before reinstalling it. Ensure that the printing temperature is correctly set for the specific type of filament being used.
- Filament degradation may result from extended idling at high temperatures. Use High-Quality Filament: Make an investment in high-quality filaments with fewer impurities and uniform diameters. To avoid contamination or moisture absorption, store filament correctly.
- To minimize the risk of molten filament solidifying in the nozzle, decrease the retraction distance and speed.
- For every type of filament, test and adjust the retraction settings. To remove impurities and leftover material, utilize specialized cleaning filament with a nozzle flush.
- Clean the nozzle frequently in between prints, particularly when changing the type of filament. To ensure even feeding, check the extruder gear for any dirt or filament debris.
- As necessary, clean or swap out any broken extruder parts.
Pro Tips:
Regular cleaning of your nozzle prevents the accumulation of clogs over time.
To prevent dust from reaching the nozzle, insert a small sponge or foam block in the filament path.
Having extra nozzles allows for quick replacements during troubleshooting.
By implementing the suggested solutions, you can ensure consistent extrusion, smooth filament flow, and high-quality 3D prints.
3D printer nozzle clogs can result from various factors including the build-up of filament residue from older or inferior filaments, improper printing temperatures, contaminants introduced by dirt or dust in the filament, and residue from switching between incompatible filament types.
A clogged nozzle in 3D printing obstructs filament flow, leading to poor print quality or printer damage.
To resolve this, perform a cold pull by heating the nozzle, extruding filament, cooling, and pulling it out to remove debris.
If needed, use a thin cleaning needle carefully to dislodge blockages without damaging the nozzle.
To maintain a 3D printer, clean the nozzle by soaking it in acetone for ABS or heating it for PLA/PETG, then use a cleaning filament or soft brush.
Ensure the printing temperature matches the filament type and avoid idling at high temperatures.
Use high-quality, consistently sized filaments and store them properly to prevent contamination and moisture absorption.
To optimize 3D printing, adjust retraction settings by reducing distance and speed, test settings for various filament types, and regularly clean the nozzle with specialized cleaning filament.
Inspect the extruder for dirt and debris, and clean or replace damaged parts as needed.
Pro Tips:
Include regular nozzle cleaning to prevent clogs, using a filament filter to eliminate dust, and having spare nozzles for quick replacements.
These practices promote smooth filament flow, consistent extrusion, and high-quality prints.
Supports Breaking Apart
Cause:
- Weak adhesion of supports to the print bed can lead to them becoming loose during printing.
- Low-density supports during printing can break or become unstable due to insufficient support density.
- Incorrect support types or placements can lead to instability due to unsuitable patterns or positioning.
- High print speed may lead to brittleness or inadequate bonding in supports if printing is performed too quickly.
- Problems with support design can arise when supports are placed at sharp angles or are overly thin, leading to potential failure.
Solution:
- Ensure proper bed adhesion by using tools like painter’s tape or glue sticks, and leveling the bed correctly for optimal initial layer attachment.
- To enhance slicer settings, increase support density, utilizing intermediate levels of 15–25% for a balance of strength and ease of removal.
- Optimize support placement by manually positioning supports using slicer tools and adjusting overhang angles to ensure supports are produced where needed.
- To enhance stability in structures, consider using grid, zigzag, or tree support patterns, with tree supports often being the most durable and material-efficient for complex designs.
- To improve layer bonding and stability in 3D printing, reduce the print speed for supports to 40–50% of the primary speed. Ensure overhang angles are checked, aiming to minimize excessive overhangs (over 60°). Incorporating design features like fillets or chamfers can also help reduce the necessity for supports.
- To enhance support materials, adjust the extrusion width and layer height for added strength, and utilize a greater extrusion multiplier for support structures.
- Select high-quality filament to ensure the strength of support structures, and ensure the filament is clean and dry.
Support structures in 3D printing are essential for models with complex shapes or overhangs, as they prevent incomplete models and enhance print quality by ensuring proper support during the printing process.
Weak adhesion to the build plate, insufficient support density, incorrect support type or placement, high print speed, and poor design of overhangs or supports contribute to the failure of 3D printing supports.
These factors can lead to supports coming loose, becoming unstable, or breaking during the printing process.
To ensure proper bed adhesion during printing, use adhesive aids such as painter’s tape, glue sticks, or a hot bed, and ensure the bed is leveled correctly for the initial layer.
Increase the support density in slicer settings for a robust output, testing intermediate levels (15–25%) for balance between strength and removal ease.
Optimize support placement by adjusting overhang angles and manually inserting supports where necessary.
Experiment with support patterns like grid, zigzag, or tree to enhance stability, particularly in complex structures, while also lowering print speed for supports.
To enhance layer bonding and stability in 3D printing, slow down support printing to 40–50% of the primary print speed and verify overhang angles.
Design models to minimize excessive overhangs, particularly those over 60°, by incorporating fillets or chamfers.
Adjust support material settings by modifying extrusion width and layer height for sufficient strength, and use a slightly higher extrusion multiplier for support structures.
It is crucial to select high-quality filament, ensuring it is clean and dry, as outdated or low-quality filament can weaken supports.
Pro Tips
To enhance 3D printing quality, conduct small test prints for adjustments, carefully remove supports with tools like cutters, and consider redesigning models to minimize support needs by incorporating self-supporting angles.
These strategies can lead to more robust and reliable supports.
I conducted research on How to Solve 3D Print Ghosting & Ringing inoder to write on the piece below.
Ghosting or Ringing
Cause:
- Quick print speeds
- High jerk and acceleration settings
- Screws and belts that are loose
- Printers with unstable frames and bases
Solution:
- Cut down on the print speed
- Changing the jerk and acceleration parameters
- Tighten the loose belts.
- Make sure the printer base is stable.
- Ghosting, also known as ringing or echoing, manifests as wave patterns on the surfaces of 3D prints, often affecting sharp edges and diminishing print quality.
- While minor ghosting may be acceptable, it can be addressed in post-processing.
- Identifying and resolving the causes of ghosting is essential to prevent noticeable defects that can detract from the finished product.
- Ghosting in 3D printing is typically caused by the printhead moving too quickly, often due to incorrect slicer settings like high print speeds or acceleration.
- When the printhead changes direction at sharp edges, it may create resonance with other components such as the extruder, print bed, and nozzle.
- This resonance can lead to inaccuracies and uneven lines on the print surface.
- Ghosting in 3D printing often results from mechanical vibrations, necessitating the resolution of hardware issues like worn parts, loose screws, low belt tension, an unstable build plate, and a wobbly frame.
- Regular maintenance can also effectively mitigate these vibrations and prevent ghosting.
- The easiest way to resolve ghosting and mechanical vibrations in a printer is by tightening all screws. Reducing print speed in the slicer minimizes ghosting in 3D prints.
- Understanding acceleration and jerk is essential for optimizing print speed and preventing ghosting in printing.
- Acceleration determines how quickly the print head speeds up, while jerk measures the rate of change in that acceleration.
- A higher acceleration setting allows the print head to reach maximum speed more quickly, whereas a lower setting results in slower acceleration.
- The majority of 3D printers utilize belts to drive the print head on the X-axis and the print bed on the Y-axis. Issues like vibrations, ghosting, and layer shift can arise from loose or broken belts and pulleys.
- Tightening loose belts is essential for resolving these problems, although adjustment methods vary by printer.
- Ghosting and vibrations in 3D printing can be reduced by ensuring a stable platform.
- Begin by placing the printer on a level table and tightening the V-slot wheels under the print bed.
- For manual leveling, consider using stiffer springs beneath the hotbed.
- Additionally, installing anti-vibration foot pads on the printer’s corners can further minimize noise and vibrations.
General Tips:
To set up your printer effectively, check the bed leveling, extruder steps, and filament diameter regularly.
Use high-quality filament, as cheaper or older options may lead to problems.
Experiment with different configurations, including adjusting temperature, speed, and cooling based on the material and model.
By troubleshooting carefully, you can enhance print quality and resolve most 3D printing issues.
