Blog


In the intricate world of 3D printing, understanding the behavior of different filaments when heated is crucial. One key aspect is thermal expansion – the tendency of filament materials to expand upon heating. This post delves into how filament expansion can affect your prints and ways to mitigate these effects for optimal results.

Understanding Filament Expansion:

Why Filaments Expand:

  • Most materials, including those used for 3D printing filaments, expand when heated. This is due to the increased movement of molecules at higher temperatures.

Variation Among Filament Types:

  • Different filament materials exhibit varying degrees of thermal expansion. For example, ABS expands more than PLA, which can lead to different printing challenges.

Problems Caused by Filament Expansion:

Dimensional Inaccuracies:

  • Excessive expansion can lead to parts being larger than intended, causing issues with fit and assembly in multi-part projects.

Warping and Layer Separation:

  • Uneven expansion can cause parts of the print to lift off the bed (warping) or layers to separate, especially in large prints.

Nozzle Clogs:

  • In some cases, expansion can lead to excessive filament build-up around the nozzle, potentially causing clogs.

Strategies to Mitigate Expansion Issues:

Temperature Control:

  • Fine-tuning the printing temperature can minimize expansion. Lower temperatures reduce expansion but must be balanced against proper filament melting.

Heated Bed Usage:

  • A heated bed maintains a consistent temperature at the base of the print, reducing warping caused by uneven cooling and contraction.

Enclosure for Temperature Management:

  • Using an enclosure can help maintain a stable temperature around the print, minimizing rapid temperature changes that contribute to expansion issues.

Filament Selection:

  • Choose filaments with lower thermal expansion coefficients for projects where dimensional accuracy is critical.

Printing Speed Adjustments:

  • Slower printing speeds can allow for more uniform cooling and reduce the effects of expansion.

Layer Height and Wall Thickness:

  • Adjusting layer height and wall thickness can also help manage the effects of expansion.

Calibration and Testing:

  • Regularly calibrating your printer and conducting test prints can help you understand how different filaments behave on your machine.


Filament expansion when heated is a natural phenomenon in 3D printing that can lead to several issues if not properly managed. By understanding the properties of your filament and adjusting your printing process accordingly, you can significantly reduce the impacts of thermal expansion and ensure higher-quality prints.


As the temperature drops, many 3D printing enthusiasts encounter the frustrating error message: “Heater extruder not heating at expected rate.” This common issue in colder weather can halt your printing projects. In this post, we’ll guide you through troubleshooting and resolving this problem.


This error typically occurs when the 3D printer’s extruder is unable to reach the desired temperature within a certain timeframe. Cold ambient temperatures can significantly impact the printer’s ability to heat up.

Troubleshooting Steps:

Check the Power Supply:

  • Ensure your printer’s power supply is adequate and stable. Inadequate power can lead to insufficient heating.

Inspect the Heating Element and Thermistor:

  • Examine the heating element and thermistor for any signs of damage or loose connections. Replace if necessary.

Upgrade Insulation:

  • Consider adding additional insulation around the heater block. This can help maintain heat, especially in a cold environment.

Use an Enclosure:

  • Printing inside an enclosure can help maintain a consistent temperature around the printer, reducing the impact of cold ambient air.

Preheat the Printer:

  • Allow more time for your printer to preheat before starting a print. This can be particularly necessary in colder conditions.

Check for Drafts:

  • Ensure your printing area is free from drafts that could be cooling the printer.

Firmware Settings:

  • Some printers allow you to adjust the time frame for heating. Extending this time can prevent the error from triggering prematurely.

Consider a Heated Build Environment:

  • For extreme cases, especially in very cold environments, a heated build chamber might be necessary.

Preventive Measures:

Regular Maintenance:

  • Regularly check and maintain your printer’s heating system to ensure everything is in optimal condition.

Environment Control:

  • Keep your printer in an environment with minimal temperature fluctuations.

The “Heater extruder not heating at expected rate” error in cold weather can be a hurdle, but with the right approach, it’s manageable. By understanding your printer’s heating needs and making adjustments for colder temperatures, you can ensure successful prints year-round.

Achieving the perfect balance in temperature settings is crucial in 3D printing. A common issue, often misunderstood, is filament sticking inside the heatbreak, especially as we transition from warmer to cooler weather. This post explores why maintaining adequate temperature is key to preventing this deceptive problem.

Understanding the Heatbreak: The heatbreak is vital in a 3D printer’s hot end, creating a barrier between the heated and cool parts. It maintains a sharp temperature gradient, ensuring the filament remains solid where it should and melts appropriately.

The Problem of Low Temperature:

  1. Filament Sticking:
    • Insufficient heatbreak temperature can cause the filament to stick or solidify, mimicking a clog.
  2. Misdiagnosis of Issues:
    • This sticking is often mistaken for a nozzle clog, leading to unnecessary troubleshooting.

Weather-Related Challenges:

  1. Transition to Colder Weather:
    • As temperatures drop, the ambient temperature in your printing environment can fall. This can lead to the heatbreak losing heat faster, especially if your printer is not enclosed, exacerbating the filament sticking issue.
  2. Temperature Management:
    • Managing the printer’s internal temperature becomes crucial during colder months. A stable and warm environment ensures consistent printing conditions.

Key Factors Contributing to Sticking:

  1. Inadequate Heating:
    • If the nozzle temperature is too low, the filament may not melt properly, causing friction in the heatbreak.
  2. Material Characteristics:
    • Different filaments have varying melting points. Settings for one material might not suffice for another.
  3. Printer Calibration:
    • Ensure your printer accurately reaches the set temperatures.

Addressing the Issue:

  1. Temperature Adjustment:
    • Incrementally increase the temperature until the filament flows smoothly.
  2. Monitor and Test:
    • Regularly test various temperatures with different materials.
  3. Regular Maintenance:
    • Keep the heatbreak clean to prevent residues that can cause sticking.

Filament sticking in the heatbreak, particularly during the colder months, is a problem that can be mistaken for a nozzle clog. Understanding filament properties and correctly calibrating your printer’s temperature can prevent this issue, ensuring reliable 3D printing experiences.

As the climate shifts to colder temperatures, it’s crucial for 3D printing enthusiasts to understand how this change impacts printing parameters, particularly retraction settings. Retraction, a key factor in preventing stringing and oozing, can behave differently in colder environments. Let’s dive into how you can adjust your retraction settings for optimal printing during the colder months.

Understanding Retraction: Retraction is the process where the printer pulls back the filament during travel moves to prevent unwanted stringing or oozing. The efficiency of retraction can be influenced by ambient temperature.

Effects of Cold Weather:

  1. Filament Temperature Dynamics:
    • Cold weather can cause the filament to cool down more rapidly, affecting its viscosity. This change might require tweaking the retraction speed and distance to compensate for the altered flow properties.
  2. Printer’s Heat Management:
    • In colder conditions, your printer may struggle to maintain consistent temperatures, leading to fluctuations that impact retraction effectiveness.

Adjusting Retraction Settings:

  1. Increase Retraction Distance:
    • If you notice more stringing in cold weather, a slight increase in retraction distance might help. Be cautious not to over-retract, as this can lead to clogs.
  2. Modifying Retraction Speed:
    • A colder environment might require adjusting the retraction speed. A slower retraction speed can allow for a more consistent filament control, reducing the likelihood of issues like oozing.
  3. Temperature Calibration:
    • Consider slightly increasing the nozzle and bed temperatures to counteract the ambient cold. This helps maintain a stable printing environment.

Environmental Control:

  1. Enclosure Use:
    • Using an enclosure can mitigate the impact of cold weather. It helps maintain a consistent temperature around the printer, reducing the need for drastic retraction setting adjustments.
  2. Humidity Considerations:
    • Colder weather often comes with changes in humidity, which can affect filament properties. Keep your filaments dry and stored properly.

Adapting to the colder climate by fine-tuning your 3D printer’s retraction settings can significantly improve your printing results. Pay attention to the temperature and humidity, and don’t hesitate to experiment with retraction settings to find what works best in your specific environment.

Transitioning to an all-metal nozzle in your 3D printer? While these nozzles offer durability and precision, they also bring a unique challenge: heat creep. This post delves into what heat creep is and how to manage it effectively.

What is Heat Creep? Heat creep occurs when heat travels up from the hot end of the nozzle to the cooler parts, causing the filament to soften or melt prematurely. This can lead to clogs and printing inconsistencies, particularly in all-metal nozzles due to their superior heat conduction.

Key Considerations:

  1. Proper Cooling:
    • Ensure your printer’s cooling system is efficient. Upgrading to a high-quality cooling fan can significantly reduce heat creep.
  2. Optimal Temperature Settings:
    • Experiment with lowering the printing temperature. Just enough to properly melt the filament but not so much that it exacerbates heat creep.
  3. Filament Choice:
    • Some filaments are more prone to heat creep. Materials like PLA, which have a lower melting point, might need more attention compared to others like ABS or PETG.
  4. Regular Maintenance:
    • Keep the nozzle and extruder clean. Accumulated debris can worsen heat creep.
  5. Thermal Break Efficiency:
    • The thermal break or throat is crucial in preventing heat transfer. Make sure it’s in good condition and consider upgrading if necessary.

Managing heat creep in all-metal nozzles is about balance. Proper cooling, correct temperature settings, and regular maintenance play vital roles. With these tips, you can enjoy the benefits of an all-metal nozzle without the headache of heat creep.

Struggling with a clogged 3D printer nozzle? Our quick guide will help you clear it out and get back to printing in no time.

Understanding Clogs:
Clogs happen due to incorrect printing temperatures, low-quality filament, or material buildup. Knowing the cause can help prevent future clogs.

Step-by-Step Guide:

Preparation:

    • Turn off and unplug your printer.
    • Gather needle-nose pliers, a cleaning needle, and a wrench.

    Initial Cleaning:

      • Remove the filament and heat the nozzle to the filament’s melting point.

      Manual Unclogging:

      • Gently use the cleaning needle to dislodge the clog.

      Advanced Techniques:

      • ‘Cold Pull’ Method: Use nylon filament to pull out the clog.
      • Chemical Solvents: Use cautiously for plastic clogs.

      Reassembly and Testing:

      • Put the nozzle back together and conduct a test print.

      Preventive Measures:

      • Opt for high-quality filament.
      • Regularly clean the nozzle.
      • Monitor printing temperatures.


      Tackling a nozzle clog is manageable with the right approach. Regular maintenance is key to preventing clogs. Get back to smooth printing with these tips!

      I enjoy 3d printing, but sometimes it’s just not the right way to make something. Today, I thought I’d give a couple of examples of some common manufacturing processes.

      Manufacturing is the process of transforming raw materials into finished products that can be used for various purposes. There are many different types of manufacturing processes, each with its own advantages and disadvantages. In this blog post, we will briefly introduce some of the most common manufacturing processes, including 3D printing, and explain when each one may be applicable.

      • Casting: Casting is a process where molten metal is poured into a mold and allowed to solidify. The mold can be made of metal, ceramic, sand, or other materials. Casting is one of the oldest and simplest manufacturing processes, and it can produce complex shapes with high accuracy and low cost. However, casting also has some limitations, such as the need for high temperatures, the possibility of defects and shrinkage, and the difficulty of recycling the waste material.
      • Forging: Forging is a process where metal is heated and then hammered or pressed into a desired shape. Forging can increase the strength and durability of metal by aligning its grain structure and eliminating air pockets. Forging can also produce parts with high dimensional accuracy and surface finish. However, forging also requires high temperatures and forces, which can limit the size and complexity of the parts.
      • Machining: Machining is a process where material is removed from a workpiece using a cutting tool or machine. Machining can create precise and intricate shapes with high surface quality and tolerance. Machining can also work with a variety of materials, such as metals, plastics, wood, ceramics, etc. However, machining also has some drawbacks, such as the high cost of tools and machines, the generation of waste material, and the possibility of tool wear and breakage.
      • 3D Printing: 3D printing is a process where material is deposited layer by layer to create a three-dimensional object. 3D printing can create complex shapes that are difficult or impossible to make with other processes. 3D printing can also reduce material waste and enable customization and personalization. However, 3D printing also has some challenges, such as the high cost of printers and materials, the low speed and resolution of printing, and the limited range of materials that can be printed.

      These are just some of the most common manufacturing processes that are used in various industries and applications. Depending on the requirements and specifications of the product, different processes may be more suitable than others. Therefore, it is important to understand the characteristics and trade-offs of each process before choosing one for your project.

      3D printing enthusiasts know that filament quality is paramount. But how can you tell if your filament has become damp? Here are the tell-tale signs:

      1. Brittleness: When filament absorbs moisture, it can become brittle and snap easily.
      2. Stringing: Moisture in the filament turns to steam during printing, causing fine strings of plastic between printed parts.
      3. Popping or Hissing Sounds: As the filament passes through the hot end, moisture evaporates, creating audible pops.
      4. Dull Finish: Instead of a smooth, shiny surface, your prints may have a rough, matte finish.
      5. Poor Adhesion: Damp filament may not stick well to the bed, leading to warping or misshapen prints.

      And the problems aren’t just cosmetic:

      • Clogged Nozzles: The steam can cause bubbles that solidify inside the nozzle, leading to blockages.
      • Weak Prints: Moisture can degrade the integrity of the plastic, resulting in weaker structural strength.
      • Reduced Precision: Inconsistent extrusion due to moisture can lead to inaccuracies in the print dimensions.

      To ensure the best printing results, store your filament in a dry, airtight container with desiccants. If your filament does get damp, all is not lost – consider using a filament dryer or oven to carefully remove moisture before printing.

      In the vibrant tapestry of “Thor: Ragnarok,” the costumes stand out as marvels of modern technology, thanks to the pioneering efforts of Wētā Workshop. This Wellington-based powerhouse collaborated closely with the film’s renowned costume designer, Mayes Rubeo, to infuse the armor and weaponry with a Jack Kirby-inspired palette that’s both bold and bright​​.

      For the Grandmaster’s elite guard, Wētā Workshop crafted sixteen suits, each a kaleidoscope of cyber-futuristic splendor in yellow, red, green, and purple, delivering a visual feast that matched Taika Waititi’s vivid comic book vision​​.

      The main attraction, Thor’s gladiator helmet, boasts wing cheek guards that animate with a life of their own. This, along with a mammoth Hulk helmet, exemplifies Wētā’s 3D printing prowess, creating pieces of a scale and detail that traditional methods could scarcely dream of​​.

      Even New Zealand’s own Karl Urban, who portrayed Skurge, was fitted for a bespoke suit of blue armor, showcasing a beaten metal finish and underlying muscle structure, all testament to Wētā’s commitment to craftsmanship and detail​​.

      “Thor: Ragnarok” wasn’t just a blockbuster hit; it was a showcase of how 3D printing is revolutionizing costume design, allowing artisans to dream bigger and bolder — a true testament to the limitless potential of additive manufacturing in the cinematic arts.

      In “Jurassic Park III” (2001), a scene showcases the use of 3D printing where a character, Billy Brennan, uses a rapid prototyper to 3D print a Velociraptor resonating chamber. He describes the process as taking scan data from a raptor skull, which the computer then breaks down into thousands of slices to be sculpted one layer at a time by the printer【20†source】. This portrayal reflects the actual capabilities of 3D printing, where objects are created layer by layer from digital models, a process also known as additive manufacturing.

      “I give you the resonation chamber of a Velociraptor.”
      —Billy Brennan