Author: Jonathan van Heijzen

Delamination is when the layers of the printed object separate from each other, resulting in a weak and brittle structure. Delamination can ruin the appearance and functionality of your 3D prints, and it can be very frustrating to deal with.

Causes of delamination

There are many factors that can contribute to delamination, but the main ones are:

  • Printing temperature: If the printing temperature is too low, the layers will not fuse properly and will be more prone to splitting. If the printing temperature is too high, the layers will warp and curl, creating gaps and cracks.
  • Cooling fan: If the cooling fan is too strong or too weak, it can affect the layer adhesion and cause delamination. A strong fan can cool down the layers too quickly, preventing them from bonding well. A weak fan can leave the layers too hot, causing them to deform and shrink.
  • Printing speed: If the printing speed is too fast, the layers will not have enough time to bond and will be more likely to separate. If the printing speed is too slow, the layers will overheat and warp.
  • Filament quality: If the filament is of poor quality or has absorbed moisture, it can affect the print quality and cause delamination. Moisture can cause bubbles and cracks in the filament, which can lead to weak and inconsistent layers.
  • Bed leveling: If the bed is not leveled properly, the first layer will not adhere well to the surface and will create a weak foundation for the rest of the print. A poorly leveled bed can also cause nozzle clogging and extrusion issues.

Fixes for delamination

Depending on the cause of delamination, there are different solutions that you can try to prevent or reduce it. Here are some of them:

  • Adjust the printing temperature: You can use a temperature tower to find the optimal printing temperature for your filament and printer. A temperature tower is a test print that consists of several sections with different temperatures.
  • Adjust the cooling fan: You can use a cooling fan test to find the optimal cooling fan speed for your filament and printer. A cooling fan test is a test print that consists of several bridges with different fan speeds.
  • Adjust the printing speed: You can use a speed test to find the optimal printing speed for your filament and printer. A speed test is a test print that consists of several cylinders with different speeds.
  • Replace or dry the filament: You can use a filament dryer to remove any moisture from your filament before printing. A filament dryer is a device that heats up and circulates air around your filament spool, reducing its humidity level. You can also store your filament in a sealed container with desiccants to prevent moisture absorption.
  • Level the bed: You can use a bed leveling test to check if your bed is leveled properly. A bed leveling test is a test print that consists of several squares across the bed surface.

When considering the purchase of a new 3D printer, here are some important features to consider:

  1. Print Quality: Look at the resolution in microns; the lower the number, the higher the resolution. Good print quality is essential for detailed models.
  2. Print Speed: Higher speed can mean faster production times, but it may also affect the quality of the print.
  3. Build Volume: The size of the print bed determines the maximum size of the objects you can print.
  4. Materials Supported: Ensure the printer supports the types of materials you plan to use. Common materials include PLA, ABS, PETG, Nylon, etc.
  5. Type of Printer: The two main types are FDM (Fused Deposition Modeling) and SLA (Stereolithography). FDM printers are generally more common and use a filament, while SLA printers use a resin and often provide higher detail.
  6. Bed Leveling: Automatic bed leveling can save time and effort, making the printing process easier, especially for beginners.
  7. Connectivity: Options like USB, Wi-Fi, and Ethernet can make it easier to send designs to your printer.
  8. Software: Compatible software is important for preparing your 3D models for printing. Some printers come with proprietary software, while others might use open-source solutions.
  9. Ease of Use: Look for features like touch-screen interfaces, easy assembly, and user-friendly design.
  10. Reliability: Read reviews to learn about the printer’s reliability and durability over time.
  11. Customer Support and Community: Good customer support can be crucial for troubleshooting. A strong user community can also provide tips and help.
  12. Price: Ensure that the printer offers a good balance of features for its price.
  13. Safety Features: Features like enclosed print areas and automatic shutdown can be important, especially in homes with pets or children.
  14. Upgradability: Check if the printer can be upgraded with improved parts or new features in the future.

3D printer filament is the material that is used to create objects with a 3D printer. There are different types of filament, such as PLA, ABS, PETG, Nylon, and more. Each filament has its own properties, such as strength, flexibility, durability, and temperature resistance. These properties affect how the filament behaves during the printing process and how the final object looks and feels.

One of the challenges of 3D printing is to find the optimal settings for each filament type. Some of the settings that need to be adjusted are print speed, retraction, and temperature. Print speed is how fast the nozzle moves while extruding the filament. Retraction is how much the filament is pulled back into the extruder when the nozzle moves to a different location. Temperature is how hot the nozzle and the heated bed are.

Different filaments require different settings because they have different melting points, viscosity, and shrinkage rates. For example, PLA melts at a lower temperature than ABS, but it also cools down faster and has less warping. Therefore, PLA can be printed at a higher speed and with less retraction than ABS. However, PLA is also more brittle and less resistant to heat than ABS. Therefore, PLA objects may not be suitable for outdoor or high-temperature applications.

To find the best settings for each filament type, it is recommended to do some test prints with different parameters and compare the results. Test prints can be simple shapes, such as cubes or cylinders, that can measure the accuracy, quality, and strength of the print. By testing different print speeds, retractions, and temperatures, one can find the optimal combination that produces the best print quality and performance for each filament type.

If you have just purchased a 3D printer, congratulations! You are about to enter a world of creativity and innovation. However, before you start printing your own designs, there are some things you should know to make the most of your 3D printer. Here are the top 5 things you should know:

  1. Choose the right filament. Filament is the material that your 3D printer uses to create objects. There are different types of filament, such as PLA, ABS, PETG, and more. Each one has its own advantages and disadvantages, such as strength, flexibility, durability, and temperature resistance. You should research the best filament for your 3D printer and your project before buying it.
  2. Level the bed. The bed is the surface where your 3D printer builds the object layer by layer. It is important to level the bed so that the first layer of your print sticks well and is even. If the bed is not level, your print may warp, curl, or fail. You can use a piece of paper or a digital sensor to check if the bed is level and adjust it accordingly.
  3. Calibrate the extruder. The extruder is the part of your 3D printer that pushes the filament through a nozzle and melts it. It is important to calibrate the extruder so that it extrudes the right amount of filament for your print. If the extruder is not calibrated, your print may be under-extruded or over-extruded, which can affect the quality and accuracy of your print. You can use a caliper or a ruler to measure the extruded filament and adjust the extruder settings.
  4. Optimize the slicer settings. The slicer is the software that converts your 3D model into instructions for your 3D printer. It allows you to customize various settings, such as layer height, infill density, print speed, and more. These settings can affect the quality, strength, and appearance of your print. You should experiment with different slicer settings to find the optimal ones for your 3D printer and your project.
  5. Maintain your 3D printer. Like any machine, your 3D printer needs regular maintenance to keep it in good condition and prevent problems. You should clean the nozzle, the bed, and the fans regularly to remove any dust or debris that may clog them. You should also lubricate the rods, belts, and bearings to reduce friction and noise. You should also check for any loose screws or wires and tighten or replace them if needed.

If you are thinking of buying a new 3D printer, you might be tempted to also buy some upgrades for it right away. After all, who doesn’t want to improve their printing quality, speed, and reliability? However, this might not be the best idea for several reasons.

Upgrading your 3D printer without testing it first can cause more problems than it solves. You might end up with incompatible parts, faulty installation, or unexpected results. For example, if you buy a new extruder without checking the compatibility with your printer model, you might find out that it doesn’t fit or that it requires a different firmware. Or if you install a new nozzle without calibrating it properly, you might get clogged prints or poor adhesion. These issues can be frustrating and time-consuming to fix, and they can also damage your printer or your prints.

Secondly, upgrading your 3D printer without knowing its strengths and weaknesses can waste your money and resources. You might buy upgrades that you don’t really need or that don’t make a significant difference.

Thirdly, upgrading your 3D printer without learning how to use it first can limit your creativity and skills. You might rely too much on the upgrades and not enough on your own knowledge and experience. For example, if you buy a new slicer software without learning the basic settings of your printer, you might not be able to customize your prints or troubleshoot them. Or if you buy a new filament without learning how to store and handle it properly, you might not be able to print with different colors or materials. These upgrades can be helpful and convenient, but they can also prevent you from exploring the full potential of your printer and yourself.

So what should you do instead of buying upgrades for your new 3D printer? Here are some suggestions:

  • Test your printer thoroughly before upgrading it. Make sure it works well and that you understand how it operates. Try printing different models with different settings and see how they turn out. Identify any problems or limitations that you encounter and look for solutions online or in the user manual.
  • Learn from other users before upgrading your printer. Join online communities and forums where you can ask questions and share tips with other 3D printing enthusiasts. Read reviews and watch videos of the upgrades that you are interested in and see how they perform on different printers and prints. Compare the pros and cons of each upgrade and decide if they are worth it for you.
  • Experiment with your printer before upgrading it. Try printing with different filaments, temperatures, speeds, and layer heights. See how these factors affect your print quality and performance. Adjust your slicer settings and see how they change your print results. Modify your models and see how they look on your printer. Have fun and be creative with your printer.
  • Upgrade to solve a specific problem after you have used your printer for some time.

Yesterday I posted about what can happen if your printing speed is too low. You basically end up with a big, oozy mess. Today I wanted to talk about what happens if your printing speed is too high.

What happens to the filament inside the nozzle?

The filament inside the nozzle is melted by the heat of the extruder, and then pushed out through a small opening at the tip of the nozzle. The nozzle acts like a valve that controls the flow and direction of the molten filament. The filament needs to be hot enough to flow smoothly, but not too hot to burn or degrade. The temperature of the filament also affects its viscosity, or how thick or thin it is. A higher viscosity means a thicker filament that is harder to push out, while a lower viscosity means a thinner filament that is easier to push out.

When you print at high speeds, you are asking the extruder to push out more filament in less time. This means that the filament has less time to melt and reach the optimal temperature and viscosity for extrusion. As a result, the filament may not flow properly, and may stick to the nozzle instead of adhering to the print bed or the previous layer. This can cause several problems, such as:

  • Filament curling: This is when the filament curls up around the nozzle instead of laying flat on the print bed or the previous layer. This can happen when the nozzle is too close to the bed or the layer, or when the bed or layer is not hot enough to keep the filament from cooling too quickly. Curling can lead to poor adhesion, stringing, blobs, and clogs.
  • Filament oozing: This is when the filament leaks out of the nozzle when it is not supposed to, such as during travel moves or retraction. This can happen when the nozzle is too hot, or when the retraction settings are not optimal. Oozing can lead to stringing, blobs, and poor surface quality.
  • Filament jamming: This is when the filament gets stuck inside the nozzle and prevents further extrusion. This can happen when the nozzle is too cold, or when there is dust

The solution to a lot of problems is to slow down your print speed. But, is there such a thing as too slow (spoiler alert, yes there is)?

If you think about what’s happening inside the nozzle, it makes sense. You are melting some plastic and pushing it through an orifice (the nozzle). If your speed is too high, you end up trying to push unmelted plastic. That’s a problem too, but the subject for a different post. This post is about the other extreme. When your temperature is high and your speed is low, the filament sits in the chamber for a long time.

However, if you raise your 3d printer temperature too high and go too slow, you are likely to encounter several issues. Some of them are:

  • Overheating: Printing with too high temperature can cause the filament to overheat and degrade. This can lead to clogging, jamming, or nozzle damage. It can also affect the color and appearance of the filament, making it darker or duller. Overheating can also cause thermal runaway, which is a dangerous situation where the temperature sensor fails and the heater keeps heating up uncontrollably.
  • Oozing: Printing with too high temperature and too slow speed can cause the filament to ooze out of the nozzle when it is not supposed to. This can create blobs, strings, or zits on the surface of your print, ruining its aesthetics and accuracy. Oozing can also waste filament and make it harder to clean your nozzle.
  • Warping: Printing with too high temperature and too slow speed can cause the filament to cool down unevenly on the print bed. This can create internal stresses that make the print warp or curl up at the edges or corners. Warping can affect the dimensional accuracy and stability of your print, as well as its adhesion to the print bed.
  • Cracking: Printing with too high temperature and too slow speed can cause the filament to shrink more than usual as it cools down. This can create gaps or cracks between the layers or within the walls of your print. Cracking can compromise the strength and durability of your print, as well as its appearance.
  • Jamming: Your filament is melted. When the gcode performs a retract function, it pulls melted plastic backwards, which subsequently starts to cool. It doesn’t take long for it to solidify enough to cause problems and will often get stuck.

The solution is often simple. You can either increase your speed or decrease your temperature.

3D printer stringing is a common problem that many beginners face when they start 3D printing. Stringing is when thin strands of filament are left behind on the print, creating a messy and unprofessional look. Stringing can ruin the appearance and functionality of your 3D printed objects, so it’s important to know how to prevent it and fix it.

There are several factors that can cause 3D printer stringing, but the main ones are:

  • Temperature: If the nozzle temperature is too high, the filament will melt too much and become more fluid. This makes it easier for the filament to ooze out of the nozzle when it’s not supposed to, creating strings. To avoid this, you should lower the nozzle temperature until you find the optimal setting for your filament type and brand. You can also use a cooling fan to cool down the filament as soon as it leaves the nozzle, reducing its viscosity and stringing tendency.
  • Retraction: Retraction is when the extruder pulls back the filament slightly before moving to a different part of the print. This prevents the filament from leaking out of the nozzle during travel moves, which can cause stringing. To enable retraction, you need to adjust the retraction distance and speed settings in your slicer software. The retraction distance is how much filament is pulled back, and the retraction speed is how fast it is pulled back. The optimal values depend on your printer model, extruder type, and filament material, but you can start with a retraction distance of 2-5 mm and a retraction speed of 40-60 mm/s and tweak them as needed.
  • Travel speed: Travel speed is how fast the nozzle moves from one point to another when it’s not printing. If the travel speed is too low, the filament will have more time to ooze out of the nozzle and create strings. To avoid this, you should increase the travel speed as much as possible without compromising the print quality. A good starting point is 150-200 mm/s, but you can experiment with different values until you find the best one for your printer and filament.
  • Z-hop: Z-hop is when the nozzle lifts up slightly before moving to a different part of the print. This creates a small gap between the nozzle and the print surface, which can prevent the nozzle from dragging across the print and leaving strings behind. To enable Z-hop, you need to adjust the Z-hop height setting in your slicer software. The Z-hop height is how much the nozzle lifts up, and it should be just enough to clear the print surface without causing too much vibration or noise. A typical value is 0.1-0.2 mm, but you can fine-tune it as needed.

I’m always fascinated with the medical industry. It amazes me how far we’ve come from leeches and bloodletting to the technology that is available today. Sickness and disease that would have been life ending in the past are able to be overcome and healed. Recently, 3d printing has taken the medical industry to the next level. Take a look.

  • Prosthetics and human organs: 3D printing can create customized and functional prosthetics for people who have lost their limbs or other body parts. For example, a company called Open Bionics makes 3D printed bionic arms that are affordable and stylish. 3D printing can also create artificial organs that mimic the structure and function of natural ones. For example, researchers have 3D printed a mini heart with human cells that can beat and contract.
  • Biomedical implants: 3D printing can create implants that are tailored to the patient’s anatomy and needs. For example, 3D printing can create dental crowns, bridges, and implants that fit perfectly and are durable. 3D printing can also create metal implants for bones, joints, and spine that are biocompatible and reduce the risk of infection.
  • Pharmaceuticals: 3D printing can create personalized drugs that have the optimal dosage, shape, and release rate for each patient. For example, a company called FabRx makes 3D printed pills that can contain multiple drugs in one tablet. 3D printing can also create complex drug delivery systems that can target specific tissues or organs.

You might be wondering what kind of surface you should use to print your models. You have a few different options, although some are more common than others.

Glass Bed

A glass bed is a smooth and rigid surface that can provide a flat and even base for your prints. Glass beds are usually made of borosilicate glass, which can withstand high temperatures and thermal shocks.

Advantages:

  • It can produce a glossy finish on the bottom layer of your prints.
  • It is easy to clean and maintain.
  • It is durable and resistant to scratches and warping.

Disadvantages:

  • It can be heavy and fragile, requiring careful handling and installation.
  • It can have poor adhesion with some materials, especially PLA, requiring the use of an additional compound or adhesive layer.
  • It can take longer to heat up and cool down, increasing the printing time and energy consumption.

Some of the common compounds or adhesive layers that can be used with a glass bed are:

  • Blue painter’s tape: Cheap and easy. Provides good adhesion for PLA and other low-temperature materials. Can leave residue on the print surface and need frequent replacement.
  • Glue stick: Simple, effective, and readily available
  • Hairspray: A popular option that can create a sticky coating on the glass bed. However, it can also be messy and affect the air quality in the printing area.
  • Magigoo: A specially formulated glue that can provide strong adhesion when hot and release the print when cold. However, it can be expensive and hard to find.

BuildTak

BuildTak is a thin and flexible plastic sheet that can be attached to the print bed with an adhesive backing. BuildTak is designed to offer a textured and durable surface that can work with a variety of materials.

Advantages:

  • It can provide excellent adhesion for most materials, reducing the risk of warping and curling.
  • It can produce a smooth and matte finish on the bottom layer of your prints.
  • It can last for a long time and withstand multiple prints.

Disadvantages:

  • It can be difficult to remove prints from the surface, requiring the use of a spatula or a scraper.
  • It can be damaged by sharp or abrasive tools, requiring careful handling and removal.
  • It can be expensive and hard to apply without bubbles or wrinkles.

PEI Sheet

PEI (Polyetherimide) is a thermoplastic polymer that can offer a smooth and glossy surface for your prints. PEI sheets are usually attached to the print bed with an adhesive backing or a magnetic base. PEI sheets are known for their high temperature resistance and chemical stability.

Advantages:

  • They can provide strong adhesion for most materials when heated and easy release when cooled.
  • They can produce a shiny and smooth finish on the bottom layer of your prints.
  • They can be reused for many times without losing their effectiveness.

Disadvantages:

  • They can be prone to scratching and denting, requiring gentle handling and cleaning.
  • They can lose their adhesion over time, requiring occasional sanding or reapplication.
  • They can be expensive and hard to cut or trim to fit your print bed size.