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Print Problems

If you have got to this page then chances are you are having print failures or quality issues.  You might also like to look through my other M2 pages that also discuss techniques for improving your prints.

 

Thin Wall Distortion Near Bed

I’ve been trying to print some prototype PLA parts for the Amigo case.  These need to be a good quality print because they are being used to test assembly, form and function.  The default M2 settings were causing distortion issues with thin wall sections near the bed, even when printed on a raft.

 

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Figure 1.  Thin Wall Distortion Near Base of Print

 

My first attempt at a solution was to increase support in these areas by adding manual support structures in Simplify 3D.  This did improve things however it did not resolve the problem.  The solution was to lower the M2 heated bed temperature from the default value of 70C down to 65C.  The new setting still provided excellent bed adhesion while virtually eliminating the thin wall distortion.

  • Thin wall distortion near the bed may be corrected by reducing the heated bed temperature.
     
  • Change the print orientation of the part.
     
  • Add Additional Supporting Structures.

 

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Figure 2.  Improved Print by Reducing Heated Bed Temperature

 

Echoes from Embossed Text

The next issue that I faced with the Amigo prototype cases  were echoes extending from external embossed text.  These always occurred down-stream (relative to extruder motion) of sharp changes in direction.  The echoes are very small deflections on the surface extending perhaps as much as 10 mm from the change in direction, with decreasing depth.  They are caused by damped mechanical vibration of the X and Y drives following fast changes in direction.

 

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Figure 3.  Echoes with Embossed Text (0.2 mm deep)

 

While echoes are very shallow and can be readily removed by sanding and solvent vapour sealing this does not fix the fundamental problem.  Here are some tips:

  • Make sure the belts are in good order and correctly tensioned.  Clean and lubricate the linear rails.  Examine and resolve any perceivable slop in the X and Y mechanical drives.
     
  • Reduce the outer layer print speed in Simplify 3D down from the 60% default to 20%.
     
  • Experiment with the GCode acceleration and jerk settings (M204 and M205 commands).
     
  • Change the design of the part using fillets to eliminate sudden external direction changes.

 

Banding Ripples on Vertical Walls

You may experience banding ripples on either the X, Y or X and Y axis, particularly after any machine adjustments.  This may be a symptom of inadequate drive belt tension.  The ripples will appear on walls that are perpendicular to the loose belt.

 

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Figure 4.  Clean Wall Parallel to Y Axis.  X Belt Tension is Fine

 

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Figure 5.  Banding Ripples Parallel to X Axis.  Y Belt Needs Tensioning

 

To Increase the tension slacken the appropriate four motor mounting bolts.  Press the motor using thumb-pressure to tension the belt and tighten the motor mount screws.  Note that too much tension  will result in belt stretch and undue wear of the motor and idler bearings.  Do not use a lever.  The correct tension is achieved when banding ripples disappear.  A ready measure of tension can be made by moving the axis extruder motor to the end stop and pressing with your index finger in the centre of the exposed belt.  With moderate pressure the belt should deflect to almost touch the  return side of the belt.

 

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